Connaect 2014

Transcription

Connaect 2014

THE MAGAZINE OF THE GLOBAL BBR NETWORK OF EXPERTS
Edition 8 | 2014
NEW HORIZONS –
PAST, PRESENT
AND FUTURE
Revealing how the BBR Network has
stayed one step ahead for 70 years
INNOVATIVE TUNNEL
CONSTRUCTION
Creating new approaches to deliver
Zurich rail link tunnel
UNCLOGGING
THE BOTTLENECK
Rising to the challenges of widening
a major expressway in Singapore
EUROPE’S LARGEST
LIFT BRIDGE
Realizing new infrastructure for expansion
of Europe’s biggest port at Rotterdam
GOING
UNDERGROUND
Specialist techniques for remedial
work in major Auckland sewer
www.bbrnetwork.com
The BBR Network is recognized as the leading group of specialized
engineering contractors in the field of post-tensioning, stay cable and
related construction engineering. The innovation and technical excellence,
brought together in 1944 by its three Swiss founders – Antonio Brandestini,
Max Birkenmaier and Mirko Robin Ros – continues, 70 years later, in that
same ethos and enterprising style.
From its Technical Headquarters and Business Development Centre in
Switzerland, the BBR Network reaches out around the globe and has at its
disposal some of the most talented engineers and technicians, as well as
the very latest internationally approved technology.
THE GLOBAL BBR NETWORK
Within the Global BBR Network, established traditions and strong local
roots are combined with the latest thinking and leading edge technology.
BBR grants each local BBR Network Member access to the latest technical
knowledge and resources – and facilitates the exchange of information on
a broad scale and within international partnering alliances. Such global
alliances and co-operations create local competitive advantages in dealing
with, for example, efficient tendering, availability of specialists and
specialized equipment or transfer of technical know-how.
ACTIVITIES OF THE NETWORK
All BBR Network Members are well-respected within their local business
communities and have built strong connections in their respective regions.
They are all structured differently to suit the local market and offer a
variety of construction services, in addition to the traditional core business
of post-tensioning.
BBR TECHNOLOGIES & BRANDS
BBR technologies have been applied to a vast array of different structures –
such as bridges, buildings, cryogenic LNG tanks, dams, marine structures,
nuclear power stations, retaining walls, tanks, silos, towers, tunnels,
wastewater treatment plants, water reservoirs and wind farms. The BBR
brands and trademarks – CONA®, BBRV®, HiAm®, HiEx, DINA®, SWIF®,
BBR E-Trace and CONNÆCT® – are recognized worldwide.
The BBR Network has a track record of excellence and innovative
approaches – with thousands of structures built using BBR technologies.
While BBR’s history goes back over 70 years, the BBR Network is focused
on constructing the future – with professionalism, innovation and the very
latest technology.
BBR VT International Ltd is the Technical Headquarters and Business Development Centre of the BBR
Network located in Switzerland. The shareholders of BBR VT International Ltd are: BBR Holding Ltd
(Switzerland), a subsidiary of the Tectus Group (Switzerland); KB Spennteknikk AS (Norway), BBR Polska
z o.o. (Poland) and KB Vorspann-Technik GmbH (Germany) – all three are members of KB Group (Norway);
BBR Pretensados y Tecnicas Especiales PTE, S.L. (Spain), a member of the FCC Group (Spain).
02 CONNÆCT | EDITION 8
INNOVATION
MEETS COMMITMENT
In 2014, BBR marks the 70th Anniversary of its founding which was firmly rooted in the Swiss values of technical
excellence, quality service and commitment to innovation. Seven decades later, BBR Network Members continue
to apply these principles to meet the challenges of new and often innovative projects, delivering the highest quality
construction engineering solutions around the globe.
As well as CONNÆCT 2014, this year we are producing a special BBR 70th
Anniversary magazine (see next pages) – contact your local BBR Network
Member to secure a copy.
In the Portfolio section of this edition of CONNÆCT, you will see that teams
THE MAGAZINE OF THE GLOBAL BBR NETWORK OF EXPERTS
Edition 8 | 2014
of BBR PT Specialists the world over are engaging proactively with customer
requirements to provide and maintain the infrastructure that we need to
conduct our daily lives.
Innovation and excellence can clearly be seen in recent BBR Network
projects – such as the stunning new footbridge in Auckland, New Zealand
and the widening of the Keppel Viaduct, a major highway in Singapore.
NEW HORIZONS –
PAST, PRESENT
AND FUTURE
Equally, a post-tensioned approach to buildings – with the support of qualified
professionals from within the BBR Network – is delighting customers for
Revealing how the BBR Network has
stayed one step ahead for 70 years
INNOVATIVE TUNNEL
CONSTRUCTION
Creating new approaches to deliver
Zurich rail link tunnel
commercial, residential and public buildings, as well as car parks.
UNCLOGGING
THE BOTTLENECK
Rising to the challenges of widening
a major expressway in Singapore
EUROPE’S LARGEST
LIFT BRIDGE
Realizing new infrastructure for expansion
of Europe’s biggest port at Rotterdam
GOING
UNDERGROUND
Specialist techniques for remedial
work in major Auckland sewer
One thing shines through loud and clear – the BBR Network has the
specialist technology and know-how to satisfy some of the most demanding
projects on the face of the earth... and, if a solution does not already exist,
they will devise and design one! This is admirably demonstrated by
Members’ work on a city center railway tunnel in Zurich and on foundations
for a new container port on the Adriatic.
You can also check out the latest news and views in Talking BBR which,
this time, includes interviews with BBR management who share their
thoughts on aspects of the business and an overview of BBR events around
the world over the last 12 months.
www.bbrnetwork.com
Last but not least, in the Technology section, we share updates on BBR
technology and R&D, as well as information about specialist techniques –
such as MRR and tendon prefabrication – used by BBR Network Members
to deliver customer requirements effectively.
In this 70th Anniversary year especially, we would like to take the opportunity
to thank all the BBR project managers and engineers, BBR site managers
and technicians – and, of course, the senior management within each BBR
Network Member – around the world for the part they have played in carrying
both our technological development and dedication to customer service
forwards. Together, we have created a blueprint for sustainable success.
Marcel Poser
Chairman, BBR VT International Ltd
José Manuel Illescas
Vice Chairman, BBR VT International Ltd
www.bbrnetwork.com 03
BBR 70TH
ANNIVERSARY
1944-2014
TIME TRAVEL WITH BBR
The award-winning Sunniberg Bridge – near the Swiss alpine ski resort
of Klosters – represents the culmination of years of technological
development at BBR, combined with the skills and inspiration of leading
Swiss designer Christian Menn. The story of the realisation of this bridge,
along with many other articles about BBR's great past, present – and
future – will shortly feature in a special 70th Anniversary magazine which
will mark our milestone anniversary.
Prepare to be amazed at the innovation
always keeping one step ahead, still has
applied by BBR in the early days and wonder
the very latest technology – and an
at the ambitious schemes undertaken.
innovative business model which reflects
It's a breath-taking journey through:
the current and upcoming needs of the
• world-record construction projects of
global market place.
every size, shape and type
• collaboration with some of the world's
greatest engineers and architects
• evolution of the BBR business
This special edition examines the earliest
days of BBR technology, its development
over the past 70 years, our Swiss roots and
values, plus an insight into some of the
model into the world's first franchise
pioneering techniques and most exciting
of its kind
projects, as well as offering a glimpse into
BBR has a stunning heritage stretching
the future. Copies are available from your
back over seven decades and today, by
local BBR Network Member.
ANNIVERSARY
QUIZ
Test your knowledge of BBR and let
us know if you can name the projects
shown in the following photographs.
To receive a special BBR 70th
Anniversary prize, the winning
entrant must identify all five projects
correctly – stating the project name
and its location. Entries should be
sent to info@bbrnetwork.com and
must be received by 31st July 2014.
1
2
3
4
5
CONTENTS
EDITORIAL, SOURCES
AND REFERENCES
07
TALKING BBR
08 BUSINESS REVIEW
11
CONFERENCE NOTES
12 A YEAR TO REMEMBER
14 PERSPECTIVE
15
PORTFOLIO
16 BRIDGES
EDITORIAL OFFICE
BBR VT International Ltd
Technical Headquarters and Business Development Centre
Switzerland
www.bbrnetwork.com
info@bbrnetwork.com
EDITOR
Jane Sandy
CONTRIBUTING EDITOR
Juan Maier
DESIGNER
Jenny Chillingworth
58 MRR
CONTRIBUTORS
George Ajaman, Kresimir Bogadi, Norbert Bogensperger, Antonio Caballero,
Chee Cheong Chang, Ron van Dijk, Lee Jian Feng, Richard Gaskill, HM Goh,
Christophe Gout, Peter Higgins, Warwick Ironmonger, Tomasz Jendernal,
Sean Kelly, Tan Yeow Koon, Chuen Lin Lee, Bartosz Lukijaniuk,
Behzad Manshadi, Valentina Mihajlovic, Claude Néant, Tim Pahapill,
Fabian Persch, Jan Piekarski, Vince Ponzio, Thomas Richli, Mark Sinclair,
Rey Singh, Stig Sjolbør, Oliver Smith, John Taraldsen, Tore Thorstensen,
Guillaume Wastiaux, Paul Wymer, Janelle Yeo
TECHNOLOGY
PUBLISHER
NUMBER OF COPIES
8,000
33 BUILDINGS
44 STAY CABLES
47 TANKS & SILOS
50 SPECIAL APPLICATIONS
63
64 RESEARCH & DEVELOPMENT
68 TECHNICAL UPDATE
70 TECHNIQUES
72 INSIGHT
77
BBR DIRECTORY
Every effort is made to ensure that the content of this edition is accurate
but the publisher accepts no responsibility for effects arising there from.
p-ISSN 1664-6606
e-ISSN 1664-6614
© BBR VT International Ltd 2014
SOURCES AND REFERENCES
Portfolio section
Crushing victory:
www.cimentsdelarochelle.fr (accessed January 2014)
Reviving a bold statement:
www.theparabola-kensington.co.uk/the_parabola_book.pdf
(accessed January 2014)
Symbol of progress:
www.euroinfrastructure.eu & www.premier.gov.pl (accessed January 2014)
Containing strength for Adriatic:
www.portauthority.hr (accessed January 2014)
This paper is manufactured with 15% recycled fibre, FSC certified.
All pulps used are Elemental Chlorine Free (EFC) and the manufacturing mill
is accredited with the ISO14001 standard for environmental management.
Vegetable based inks have been used and 85% of all waste associated with
this product has been recycled.
TALKING BBR
08 BUSINESS REVIEW
Thomas Richli and Dr. Antonio
Caballero share observations on
the past and visions for the future
11 CONFERENCE NOTES
reflections on the 2013 Annual
Global BBR Conference in Auckland,
New Zealand, shared by Juan Maier,
from BBR HQ
12 A YEAR TO REMEMBER
a small selection of BBR Network
highlights from around the globe –
events, awards and training
14 PERSPECTIVE
BBR VT International’s newest
Board member, Tore Thorstensen,
offers his take on what makes the
BBR Network so successful
TALKING BBR
BUSINESS REVIEW
BBR VT’s senior executives reflect on learning and direction
NEW
HORIZONS –
PAST, PRESENT
AND FUTURE
The 70th Anniversary of BBR’s founding in 2014 presents an interesting
opportunity to reflect on the past, the present and the future.
BBR VT International Ltd’s CEO, Dr. Antonio Caballero and Thomas Richli,
Chief Business Development Officer, share their observations and visions
for the future.
Why is history relevant to today – and to
and then, with the enthusiasm and support
the future?
of contacts, commercialized it globally.
TR: People sometimes say that we need
As time passed, they saw opportunities
to understand where we have been, so that
to expand the range of technology – and,
we can understand where we need to go.
through the foundation of Proceq, even
In the case of BBR, it’s clear that when
developed a range of equipment to help
Max Birkenmaier, Antonio Brandestini and
in their work.
Mirko Robin Roš began the partnership
they knew they had created something
AC: Our history gives us our identity – our
special – something useful – and they were
founders’ interest in and their passion for
taking the right steps to ensure their ideas
coming up with something new certainly
would be developed further.
continue today. Back then, the business
They were creating something which did not
was technology driven, today it is driven
exist before, their goal was the development
by customer needs. However, the quest
of new and reliable construction technology.
for further knowledge and improvement
They networked energetically on the
on all fronts will never end – the journey
architecture and construction engineering
begun in the 1940s will continue long into
scene to raise awareness of their technology
the future.
TALKING BBR
What are the main differences in BBR’s
position today compared to 70 years ago?
TR: Perhaps the biggest thing is that the
BBR brand is now recognized the world
over. Most engineers know the BBR brand
and recognize it represents quality Swiss
engineering technology. Thus, our Network
Members experience a positive acceptance
of BBR technology by their customers.
The BBR reputation for quality and reliability
has been won over 70 years – this is a
great advantage for the BBR Network.
AC: As well as quality, the BBR brand also
represents the latest technology, qualified
professionals and experience gained in
literally thousands of applications. Another
major difference is the Global Network of
Experts we have established over recent
years and will continue to strengthen. Of
course, harmonization of standards –
embodied by EC and ETA – has also
occurred. This was one reason why the BBR
Network was established – to share costs
and focus. BBR HQ provides a full package
of latest technology including development,
testing, approval and supply chain as well as
related services such as marketing support,
brands, publications, training seminars and
so forth for its Members. This enables
Members to concentrate on local sales,
installation and engineering.
TR: These issues are important because
they allow BBR Network Members to
focus on their work, rather than becoming
distracted by supply or regulatory issues.
Ultimately, it allows them to provide the
best possible service to their customers.
How do today’s challenges compare with
those the BBR founders faced?
AC: The first challenges were purely
technological and probably the greatest
challenge – to create new technology such
as BBRV from scratch and build a reputation
for it. Now the situation is different, BBR
technology has been used for years in many
countries. The challenge today is to find new
ways of using the technology. For example,
the use of external post-tensioning for
strengthening structures is a comparatively
recent innovation which relates our
technology to current needs. Extending the
lifetime of mature structures is becoming a
major issue today, particularly in Europe.
All over the world, BBR technology is being
used for new applications that simply did
not exist back then – like using posttensioning in the construction of towers for
wind energy projects. ➤
TALKING BBR
TR: In the past, the economic situation
TR: There has been a shift, not just in
was completely different. After the Second
construction, but in every industry towards
World War, there was huge demand
a more customer-focused business
– people needed road and rail networks –
environment. A deeper understanding of
and a shortage of materials, engineers and
the needs of customers has become vital for
reliable technology. Today, cost pressures
conducting successful business. Along with
are perhaps greater than, say, six decades
this, organizations should be able to supply
ago – and the world has become a more
a complete service – whether the job is small
complex global trading environment. A
or large. This is where having strong back up
large percentage of money invested in
and access to an international organization –
infrastructure or buildings goes into
such as the BBR Network – helps in forming
strengthening or renovation. Different
the right package or offering and this also
techniques, equipment and know-how are
keeps us constantly innovating. In fact, one
needed for these and the Network can
of the main strengths of the BBR Network
provide the expertise to meet this demand.
is that its Members are locally based
The BBR Network today is able to offer a
companies and professionals who have
wider range of complex construction
strong local knowledge, yet have the backing
engineering solutions beyond post-
of an international ‘Network of Experts’.
tensioning and stay cables (see also pages
72-75). Cost-efficiency is the order of the
What factors do you think will bring
day and here, at BBR HQ, we too are always
success in future decades?
looking for ways to optimize costs for the
AC: The wealth of know-how that has
BBR Network, to give our Members greater
accumulated over the past seven decades
opportunity to be even more competitive.
is significant. It will continue to grow and to
1
feed our commercial and technological
AC: Yes, we are evaluating ways of further
development in the future. Innovative
streamlining cost blocks, such as material
know-how – and the way in which it is
sourcing, equipment, logistics and
shared and used – will increasingly become
centralized teams or services and where
a differentiating factor for successful
there is an advantage, we will make
organizations. That’s why we place so much
changes. With the transformation of the
emphasis on creating new opportunities,
corporate business model to a franchise
networking with other organizations,
system, centralization of certain functions
developing channels and resources for
makes sense as it saves time, effort and
the exchange of information – this is
costs. Reducing duplication of effort has
something we are constantly reviewing,
been at the heart of our approach in this
refining and extending.
context and, while there is yet more work to
do, efficiencies have already been achieved.
TR: As I mentioned earlier, listening and
responding closely to customer
And what have been the most significant
requirements is essential to ensuring future
changes in the market?
business success. We are always striving to
AC: The obvious change is that the market
do this – and, again, if you look back at
is now a highly competitive global one in
BBR’s history, this is what we have always
which the benefits of post-tensioning and
done. BBR may have started with a simple
stay cable technologies are generally well-
prestressed beam, but progressively grew
understood and established. Today, what
the technology – in response to changing
the BBR Network can offer as a package is
customer requirements – into a full range
massive. For example, packages have
of technologies supporting both private
included bridge construction techniques
and public sector clients all over the world.
and services, linked with provision of bridge
And, of course, BBR also developed an
construction equipment, PT bars and so
entire global Network to ensure quality
on. The Network continuously increases
implementation of construction technology-
the scope to deliver tailored solutions and
based solutions.
meet customer needs more effectively.
So, key factors are having an excellent
Collaborative ventures between BBR
understanding of the market needs,
Network Members are occurring more-
continuous innovation and excellent quality
and-more frequently and we see the basis
to bring added value for our customers –
for this at BBR Network gatherings.
this is where we need to go. ●
1 Dr. Antonio Caballero – CEO, BBR VT
International Ltd (top). Thomas Richli
– Chief Business Development Officer,
BBR VT International Ltd (bottom).
TALKING BBR
ANNUAL BBR GLOBAL CONFERENCE, AUCKLAND, NEW ZEALAND
Technical updates, networking and knowledge exchange
CONFERENCE
NOTES
The 2013 Global BBR Conference in Auckland, New Zealand was always
In session
Formal conference proceedings were
opened by Thomas Richli who outlined the
program and officially welcomed the new
Swiss franchisee, Stahlton Ltd, to the BBR
Network and introduced their Product
Manager PT, Fabian Persch who gave an
overview of the Swiss market place. Next
was a presentation by Vanesa Salva from
local BBR Network Member, BBR Contech,
about the innovative Pres-Lam technology
set to be a stunning event – taking place as it did in the local BBR Network
which combines post-tensioning with
Member’s 50th Anniversary year. BBR VT International’s Senior Business
laminated veneer lumber (LVL) for a
Development Manager, Juan Maier, presents a report of the occasion.
seismically resistant construction solution.
As well as BBR news, technology updates
and workshops, the conference featured
2013 BBR AWARD WINNERS
BBR NETWORK PROJECT OF THE YEAR
Rio Corgo Viaduct, Portugal,
executed by BBR PTE (Spain)
BEST ARTICLE AWARD
Joint winner: BBR PTE (Spain)
Title: Waltzing over the Danube
(Danube Bridge 2 in Bulgaria &
Romania)
Most importantly of all, the Annual
further keynote presentations about the
Global BBR Conference is about getting
benefits of PT for developers (Marcel
all delegates together under one roof, to
Poser, Tectus), Kuala Lumpur LRT
gather the opinions of people with much
Extension project (King-Bang Tie, BBR
industry experience and wisdom. The
Malaysia) and Sudan’s Roseires Dam
ultimate goal – for all of us – is to improve
project (Mark Sinclair, SSL Australia).
our operations and way we go to market
Guest speaker, Stuart Oliver of Holmes
in the future.
Consulting delivered a most informative
session on seismic retrofit with PT.
Joint winner: ETIC (France)
Tee-ing off
As always, there were ample opportunities
Title: Highway to the snow
(Bellegarde Viaduct, A40 Geneva
to Lyon section of the A4 motorway
in France)
The Conference began, as is now
for networking between BBR Network
customary, with the BBR Charity Golf
Members and the Conference concluded
Tournament which highlighted a wide
with site visits – taking in PT, MRR and
Highly commended: BBR Polska
(Poland)
range of skills and abilities – and provided
slab-on-ground projects in the city.
an opportunity to get people talking. As
For me, one of the highlights was the
Title: Symbol of development &
modernity (Przemysl Bridge,
Southern Poland)
delegates tee-ed off for the eight and ninth
emergence, during our training sessions,
holes of this stunning coastal golf course,
of another PT Grand Master – Rob
the concentration of even the most focused
Robinson of BBR Contech made the grade
player was challenged as they faced the
and joins a select group of highly skilled
dramatic view of waves crashing at the
and experienced engineers with
foot of the cliffs opposite. The event
outstanding knowledge of the application
literally got the ball rolling for a lively and
of BBR post-tensioning systems. It would
informative conference – while
be wonderful to be able to make a similar
emphasizing the importance of continuous
award this June, at our 2014 Global BBR
performance improvement to some of us!
Conference in Interlaken, Switzerland. ●
BEST PHOTOGRAPHY AWARD
Winner: SSL Structural Systems
(Africa)
Runner up: BBR Construction Systems
(Malaysia)
Highly commended: Spanstaal –
Ballast Nedam Infra Specialiteiten B.V.
(Netherlands)
www.bbrnetwork.com
11
TALKING BBR
NEWS HIGHLIGHTS
Awards, events and more
A YEAR TO
REMEMBER
There was much to celebrate and many activities in-and-around the BBR Network during 2013.
Here, we present a brief selection of some of the year’s highlights.
Fifth annual BBR Adria PT Seminar
range in practical and classroom scenarios,
In June, the fifth annual BBR Adria Post-
as well as sharing best practices in
tensioning Seminar was held in Zagreb,
operational management, trouble-shooting
Croatia – adjacent to two award-winning
on site, procurement practices and
buildings constructed with BBR technology.
improvement of productivity during
The audience included engineers, architects
break-out knowledge sharing workshops.
and designers from around the region.
Among the guest lecturers was BBR VT
Golden Anniversary
International’s Antonio Caballero who
BBR Contech, the BBR Network Member
spoke about the benefits of the BBR VT
in New Zealand, celebrated five decades
CONA CMX range in terms of sustainability,
of service to the construction industry –
as well as some key points for design.
a half century in which it has earned an
outstanding reputation for post-tensioning,
Workshop highlights operational success
ground anchoring, seismic strengthening,
A highly successful project managers’
construction engineering and structural
course was held during August in Brisbane,
maintenance, repair and retrofitting.
Australia. The 20 BBR engineers from
The company held 50th Anniversary
Singapore, Malaysia, New Zealand and
functions – attended by staff, directors,
Australia studied the technical aspects of
key clients and partners – in Auckland,
the BBR VT CONA CMX post-tensioning
Wellington and Christchurch.
TALKING BBR
1
2
3
5
4
Singapore celebrations
BBR Holdings (S) Ltd, parent company of
BBR Network Member, BBR Construction
Systems, marked two decades of operations
in September with a celebration dinner,
European Project Manager's
attended by some 800 guests, at the Marina
Workshop in Zagreb
Bay Sands Grand Ballroom, Singapore.
The most recent European Project
The organization has grown beyond its
Managers’ Workshop saw engineers from
original specialist engineering roots to offer
across Europe gathering in Zagreb, Croatia
civil and building works, as well as being a
for three days. This year's session focused
boutique developer in this region.
on PT slabs and covered a broad range of
topics – including slab design
Excellence award
considerations, marketing and offering for
The 2013 ASBI Bridge Award of Excellence
PT slab projects, as well as procurement
has been awarded to the Danube Bridge 2
and installation. The whole team was also
in Vidin-Calafat (Bulgaria / Romania). This
updated on the latest news from BBR HQ,
bridge was completed by BBR PTE, Spain,
given an overview of the newest range of
who installed 2,100t of BBR VT CONA CMI
CONA CMX accessories, while also sharing
post-tensioning, 65,000m of plastic duct
best practices in break-out working groups.
and 208 BBR HiAm stay cables. It also
At the end of the workshop, delegates
featured the first use of the innovative
visited a multi-storey construction project
BBR HiEx CONA Bundle Saddle for the
site to see the BBR VT CONA CMM Single
extradosed bridge configuration.
PT anchor in action. ●
1 The Danube Bridge II in Vidin-Calafat,
Bulgaria / Romania was declared winner of
the 2013 ASBI Bridge of Excellence Award.
Photograph courtesy of FCC Construcción.
2 Singapore-based BBR Holdings' 20th
Anniversary was marked with a celebration
dinner for 800 guests. Pictured here is
CEO Andrew Tan being presented with a
commemorative Swiss cow bell.
3 Directors of BBR Contech, the New Zealandbased BBR Network Member, joined with
staff, clients and business partners at
functions in Auckland, Wellington and
Christchurch to celebrate 50 years of
serving construction in New Zealand. Left
to right: Andrew Dallas, Des Mataga, David
Dorrington, Paul Wymer and Dr Ian Parton.
4 BBR Network engineers working together
in a break-out session during the
European Project Managers’ Workshop in
Zagreb, Croatia.
5 The BBR project managers’ training course
in Brisbane, Australia featured technical
and workshop sessions.
TALKING BBR
PERSPECTIVE
Strength and success through networking
GREATER
THAN THE SUM
OF ITS PARTS
One of BBR VT International’s
Over recent years, I have seen the
something that, personally, I find very
newest Board Members is Tore
technological developments taking place
exciting – partly because of the increased
and witnessed the securing of European
business generated by this approach for
Thorstensen, CEO of KB Gruppen
Approval for the range of CONA CMX
those Members involved and partly
Kongsvinger AS, Norway’s largest
technology. This has been a great success
because of the inevitable skills transfer
family-owned building and
for our business and – along with our other
that happens in the course of executing
construction company. He is also
well-established brands which are
the work, meaning that new technology,
internationally recognized – has placed the
techniques or applications can then be
BBR Network in a market leading position.
applied to local markets, thus opening up
a member of the Board of Plantasjen
– the largest retail garden center
new business opportunities in a Member’s
operation in Norway – where
Global network
previously he served as the working
One of the greatest strengths of the BBR
home territory.
Network is, however, the network itself.
Commitment to success
Each Member has valuable local knowledge,
While all BBR Network Members depend
that, as CEO. Earlier roles include
as well as specialist skills – gained on
on services from BBR HQ and sharing of
18 years with Dyno Industrier, a
projects particular to their region. Often,
communal knowledge, the independence
speciality chemicals producer,
Members are part of a larger organization
of franchisees’ individual businesses
which, in turn, offers further specialist
ensures the highest level of commitment
expertise and services.
to success. It is this commitment, I believe,
We asked Tore to share his
When you put all of the available expertise,
that drives many of the good things which
observations and thoughts on the
skills and specialist equipment together,
are happening within the BBR Network.
reasons for the success of the BBR
you have an organization that is truly
Now is also the time for us to expand and
greater than the sum of its parts. There is
strengthen the BBR Network by increasing
no construction challenge on the planet
our geographic coverage. We are ready to
that we could not rise to meet – together.
bring the BBR technology to territories in
chairman of the Board and before
latterly as executive vice president.
Network with CONNÆCT readers.
which we are not currently active and
Maximum opportunities
where, through changed market conditions,
The opportunities presented, through the
there are growing infrastructure needs.
BBR Network, for Members to literally
In this, BBR’s 70th Anniversary year, we
‘network’ are also a huge advantage. There
should take additional inspiration from the
can be no doubt that the information and
enterprise, innovation and dedication that
best practice shared during such occasions
the three founders applied to introduce
contributes to the excellence of the service
completely new technology to the world
we provide to our customers – a world of
market. We should continue to embrace
knowledge, applied to local markets. It’s a
that spirit in bringing established – and
win-win situation.
now the latest European Approved –
When these dialogues – whether they
BBR technology to new markets and
actually begin face-to-face or through the
applications, as well as to making our
BBR Forum or by other means – turn to
individual businesses even more successful
broader capability issues, international
through the very close ties afforded by
collaborations can often form. This is
being a Member of the BBR Network. ●
PORTFOLIO
BRIDGES
16 INTEGRATING STRUCTURE
& ENVIRONMENT
the new award-winning Point
Resolution bridge in Auckland,
New Zealand not only gives access,
but also reflects local heritage
BUILDINGS
33 EARLY INVOLVEMENT FOR
BEST SOLUTION
post-tensioned solutions for
buildings, provided with BBR
technology and know-how,
have delivered real benefits for
customers in Poland
STAY CABLES
44 SYMBOL OF PROGRESS
The new Przemysl Bridge, officially
opened by the Polish Prime Minister,
featured incremental launching and
BBR HiAm CONA stay cables
TANKS & SILOS
47 BUILDING FOR BIOGAS
four massive digester tanks for
biogas production in Hungary
have been realized with BBR VT
CONA CMM post-tensioning
SPECIAL APPLICATIONS
50 SLIDING WITH SAFETY & SPEED
Lateral bridge sliding was chosen
to minimize impact on rail traffic
during a regional railway link project
in Western Australia
MRR
58 GOING UNDERGROUND
maintenance work on Auckland’s
19km long Eastern Interceptor
Sewer required the team to work
inside the large wastewater pipe
PORTFOLIO BRIDGES
POINT RESOLUTION TAURARUA FOOTBRIDGE, AUCKLAND, NEW ZEALAND
Award-winning post-tensioned concrete and steel pedestrian bridge
INTEGRATING
STRUCTURE AND
ENVIRONMENT
1
PORTFOLIO BRIDGES
An unassuming yet elegant pedestrian bridge giving access to Auckland’s
Parnell Baths, across railway tracks and the busy Tamaki Drive – which
links the Point Resolution headland to the City’s eastern suburbs, across
Hobson Bay – has won the New Zealand Concrete Society’s coveted
2013 Monte Craven Architectural Building Award. BBR Contech, the BBR
Network Member based in New Zealand, is pleased to have contributed
to the realization of this award-winning project.
The new Point Resolution Bridge replaces
Architectural design
one originally built in two sections to
The bridge is made up of three connected
connect Tamaki Drive with the Parnell
precast post-tensioned concrete beams –
Baths – a swimming complex built around
forming a hull-like shape which makes a
half-a-century ago and featuring the largest
visual reference and connection to the
salt water pool in New Zealand. When
harbor and yachts beyond. This structure is
engineering experts assessed the bridge
threaded through an external framework of
as having reached the end of its design life
painted steel featuring three sculpted arches
and thus in urgent need of refurbishment
– echoing the shape of the original bridge –
or replacement because of corroded
connected by simple glass balustrades.
steelwork, Auckland Council started looking
The bridge deck provides a canvas for
for a long-term solution.
specially commissioned artwork that
The end result is this glorious new structure,
incorporates a delicate water ripple – or
designed by award-winning architecture
‘pungarungaru’ – design which has been
practice, Warren and Mahoney.
cast into the formed face of the precast
beams. The ripple design continues on the
clear glass panels of the balustrades. ➤
2
PORTFOLIO BRIDGES
4
3
Elegant, clever & unobtrusive
In making their award for the Monte Craven
Architectural Building 2013, the Judging
“Fortunately, we’ve
worked with BBR
Complex construction
Panel at the New Zealand Concrete
Contech before,
The bridge’s elegant visual simplicity belies
Society said:
the complexity of the construction task
“It is an elegant, clever and unobtrusive
so we knew they
behind this project. Wilson Precast
solution. The architecture and integration of
managed the process of integrating the
structure and environment works perfectly –
detailed artwork into the precasting moulds,
and showcases what can be achieved when
coordinating all aspects of the fabrication
value is placed on building structures that
and then finally getting the 90t beams
are highly functional and in sync with the
transported to site ready for lifting – no
environment. The twin-cell post-tensioned
small feat.
concrete bridge deck achieves the large
“It was enormously challenging,”
spans, provides for low maintenance and
commented Duncan Peters, a Director of
offers a palette for incorporating the
Peters & Cheung, the bridge’s design
pungarungaru (ripples on the water) design
engineers. “Here were these enormous,
reflected throughout other parts of the
incredibly heavy concrete beams being
structure. This footbridge is a striking and
held up by virtual toothpicks – how could
memorable landmark structure that
we ensure that the structure could be built,
enhances the waterfront perspective – it is
let alone stay stable and survive a disaster
a poster child for concrete and the public
such as an earthquake?”
will spend as much time admiring the bridge
Duncan went on to say that great
as they will the beauty of the Auckland
teamwork – which included working with
landscape that surrounds it.”
Wilson Precast and BBR Contech to
Proposed by Monte Craven, The Monte
ensure integrity in the concrete beams
Craven Architectural Building Award was
through a comprehensive post-tensioning
first introduced in 1998 to encourage
process – was key to the project’s success,
engineers and architects to work more
especially given a construction timeframe
closely together on construction projects
of just 12 months.
involving concrete. The Point Resolution
The work started off-site, where the three
Bridge is a textbook example of how the
precast beams were post-tensioned using
entire professional team worked closely
tendons of between 22 and 25 strands,
together to deliver an outstanding result
each 15.2mm in diameter. The beams were
for the client and the community for years
stressed using our brand-new 700t jack –
to come.
with the largest beam stressed to 460t.
BBR Contech is delighted to have been
It was critical to get this process right,” added
involved in this exceptional project and
Duncan. “Fortunately we’ve worked with
looks forward to playing its part in further
BBR Contech before, so we knew they would
award-winning schemes along with other
deliver. It’s a credit to the whole team that
members of the professional team for the
this very complicated project went so well.”
Point Resolution Bridge. ●
would deliver.”
Duncan Peters, Peters & Cheung
1 The deck of the award-winning Point
Resolution Bridge is made up of three
connected precast post-tensioned
concrete beams – its hull-shape reflects
the maritime setting.
2 The BBR VT CONA CMI tendons in the
precast beams were stressed using a 700t
jack, with the largest beam stressed to 460t.
3 Great teamwork between Wilson Precast
and BBR Contech ensured integrity in the
concrete beams through a comprehensive
post-tensioning process.
4 The Judging Panel at the New Zealand
Concrete Society commented that the
project showed what could be achieved
when value was placed on building structures
that are highly functional and in sync with
the environment.
TEAM & TECHNOLOGY
Client – Auckland Council
Architect – Warren and Mahoney
Main contractor – Hawkins Infrastructure
Engineer – Peters & Cheung
Precaster – Wilson Precast
Technology – BBR VT CONA CMI internal
BBR Network Member – BBR Contech
(New Zealand)
PORTFOLIO BRIDGES
ROAD BRIDGES, JEDDAH, KINGDOM OF SAUDI ARABIA
Post-tensioning for two city center flyovers
EASING
TRAFFIC FLOW
Two new flyovers have been
constructed as part of a long term
plan to ease traffic flow around the
city of Jeddah and meet the needs
of the rapidly growing local
population. BBR Network Member,
Huta Hegerfeld Saudia Ltd, has
provided post-tensioning services
for both projects.
The projects are located at two intersections
along Prince Majid Road – at Thahlia Street
and Sari Street.
At the Thahlia Street intersection, a 220m
long five span bridge – featuring a main
span of 60m – has been completed. The
1
deck contains three types of precast beams
plus a cast in-situ section. Post-tensioning
for the precast sections was achieved using
BBR VT CONA CMI 0706 and 1206 systems.
The cast in-situ section was post-tensioned
with the CONA CMI 1206 system.
Meanwhile, at the Sari Street intersection,
the flyover is a 315m long eight span bridge
with a 41m main span, constructed entirely
of prestressed precast beams. The beams
were assembled in post-tensioned sets of
one or two spans each and on four
alignments. Longitudinal tendons were
BBR VT CONA CMI 0706 and 1206, while
the transversal post-tensioning for the
crossheads was provided using CONA CMI
1206 and 1906 systems.
The two projects required a total of 320
2
tendons and 360t of prestressing strand.
The completion of these two projects is a
step on the way to achieving the city’s
ultimate plan of linking Prince Majid Road
to Jeddah’s Southern Corniche. ●
1 Intersection of Prince Majid Road with
Thahlia Street.
2 Intersection of Prince Majid Road with
Sari Street.
TEAM & TECHNOLOGY
Owner – Municipality of Jeddah
Main contractor – Huta Hegerfeld
Saudia Ltd
Designer – JL Cancio Martins / Trois
Engineering Ltd
BBR Network Member – Huta-Hegerfeld
Saudia Ltd
PORTFOLIO BRIDGES
1
ACCESS BRIDGE, CAHAYA SPK COMMUNITY, SHAH ALAM, SELANGOR, MALAYSIA
Curved viaduct launching
ELEGANTLY
CURVED BRIDGE
Construction planning
As the main bridge was being constructed
directly above existing live traffic, it was
impossible to adopt the cast in-situ method
for the whole bridge – the setting up of
temporary formwork would have caused
long term closure to traffic of the highway
beneath and, thus, serious inconvenience.
Therefore, the precast method was adopted
for the main span of the bridge.
To reduce the concrete self-weight during
An elevated viaduct, over-flying an
The original viaduct design had an
launching, the casting of the main span was
existing highway, was needed to
intermediate pier at the median to handle
divided into two box girders – outer beam
the long span and tight 60m radius
and the inner beam. Each beam weighs less
provide a dedicated access to the
horizontal curve. Construction of the
than 200t.
community of Cahaya SPK, Shah
intermediate pier within the narrow median
There were three construction stages:
Alam, Selangor. BBR Construction
strip would have been disruptive to traffic
• Stage 1 – Falsework and formwork were
Systems successfully bid for this
and dangerous to both road users and the
erected to cast the approach spans.
construction contractor. As well as our
At the same time, precasting of the main
design and build project. HM Goh
keen pricing, the client liked our alternative
span beams was carried out.
of BBR Construction Systems
proposal as it removed the need for an
Malaysia explains the challenges
intermediate pier – and would also result
and grouting of the approach spans, the
surrounding this design and
in an exceptionally elegant bridge.
mid-span precast beams were launched
construct project for the 115m long
box spine curved main viaduct.
on top of the piers. Each precast beam
Bridge configuration
was hung in position by steel tie beams.
The main bridge of the viaduct has a span
Vertical 36mm diameter prestress bars
configuration of 31m + 53m + 31m. The two
approach ramps are comprised of cast
1 Challenges for the BBR team working on
this elegant bridge included safety, terrain,
buildability, aesthetics, space limitations
and time constraints.
• Stage 2 – After completion of stressing
were stressed to hold the steel tie beams.
• Stage 3 – After launching the precast
in-situ reinforced concrete structures and
beams, the deck slabs between the two
reinforced earth walling. Structurally, the
beams were stitched. The gaps between
deck is made up of two precast box girders
the ends of the precast beams and the
– which provide good torsional capacity to
approach beams were also stitched.
resist the effects from the bridge’s curved
Then the continuous BBR CONA internal
geometry. Topography and terrain of the site
1906 tendons over the three spans were
dictated that the bridge geometry required a
stressed to complete the continuous
curve of 60m radius and a pier height of 8m.
bridge superstructure.
PORTFOLIO BRIDGES
Temporary works design & consideration
Temporary steel tie beams were necessary
for the whole launching process, as it served
as the main support member until the three
span bridge was completed. The design of
the tie beams was challenging due to the
curved geometry. The center of gravity of the
precast beam was away from the centerline
of the alignment, thus the beam would tend
to rotate if lifted at the ends. Therefore, two
adjustable lifting brackets with multiple
adjustments were fabricated to ensure that
during the lifting operation, by two mobile
cranes, the original center of gravity of the
curved beam would be maintained.
In securing each beam to the approach
beam, high torsional moments and shear
forces needed to be overcome. This was
achieved by using a pair of Grade 50B steel
tie beams stressed with vertical 36mm bars.
HUNTER EXPRESSWAY, NEW SOUTH WALES, AUSTRALIA
Erection work
First use of BBR VT CONA CMI for RMS project
The launching of the two main beams was
targeted to be completed in 48 hours, as the
local authority only permitted the main road
to be closed between 12am and 7am. Hence,
the aim was to completely launch only one
beam per night.
First, the beam was lifted by two 300t
capacity cranes and placed on a multi-axle
loader. The multi-axle loader transferred the
MILESTONE FOR
BBR TECHNOLOGY
beam to the launching point. The beam was
Approval for use of the BBR VT CONA CMI system within Roads &
lifted by 400t and 500t capacity cranes.
Maritime Services (RMS) projects was granted in May 2012 and, just
When the beam was in position, stressing of
the bars was carried out to secure the beam.
six months later, explains Project Manager Vince Ponzio, of BBR
The same process was repeated for the
Network Member Structural Systems, it was being installed on a major
second beam during the following night.
freeway project in New South Wales.
Completion
The whole bridge was opened to traffic on
The Hunter Expressway is a $1.7 billion
In total, 84 post-tensioning tendons were
8 September 2013 and now has become one
40km, four lane freeway link between
installed – requiring approximately 100t
of the important landmarks of the area. Road
the F3 Freeway near Seahampton and the
of 15.2mm strand and 3.5km of ducting.
safety, challenging terrain, construction
New England Highway west of Branxton.
The new BBR VT CONA CMI system met
practicability, aesthetic value, working
The western section of the project
all client expectations resulting in a
space limitation and time constraints have
involves completion of 27km of the
highly successful project and positive
made this project both truly memorable –
new freeway link, including four grade
client feedback. ●
and extremely satisfying. ●
separated interchanges and a total of
25 bridges along its length.
Two interchanges – one located at
Kurri Kurri (pictured above) and the
other at Branxton – involved the
construction of single span, cast in-situ
TEAM & TECHNOLOGY
post-tensioned box girder bridges over
Owner – S.J Properties Sdn Bhd
Main contractor – BBR Construction
Systems (M) Sdn Bhd
Designer – Perunding LFL
Bridge contractor – BBR Construction
Systems (M) Sdn Bhd
Technology – BBR CONA internal, PT bars,
Span-by-span precast
BBR Network Member – BBR Construction
Systems (M) Sdn Bhd (Malaysia)
the new Hunter Expressway.
Structural Systems was awarded the
contract for the supply and installation
of post-tensioning services for these
bridges. Each of the four bridges
was approximately 40m in length
featuring a combination of 1906 and
3106 CONA CMI multistrand tendons.
TEAM & TECHNOLOGY
Owner – NSW Roads & Maritime
Services (RMS)
Main contractor – Abigroup Contractors
Pty Ltd
Designer – SMEC / SKM
BBR Network Member – Structural
Systems Limited (Australia)
PORTFOLIO BRIDGES
KEPPEL VIADUCT, SINGAPORE
Carriageway widening
UNCLOGGING
THE BOTTLENECK
The Keppel Viaduct – an awkward bottleneck on Singapore’s Ayer Rajah Expressway – is being
upgraded from a dual three lane carriageway to a dual four lane carriageway. Singapore-based
BBR Construction Systems’ Project Manager, Tan Yeow Koon describes the project’s history and
explains how existing site conditions make both the design and construction a major challenge.
1
PORTFOLIO BRIDGES
“...the live traffic
environment and
limitations imposed
by existing structures
made both the design
and construction a
The Keppel Viaduct was constructed as part
Post-tensioned extension
of the Ayer Rajah Expressway (AYE) from
To accommodate the widening of deck
1983 to 1988. At that time, it was the longest
slabs at both ends of the viaduct, the
vehicular viaduct in Singapore – measuring
design proposes an extension of the
2.2km in length – and a crucial traffic
existing crossbeam, such that additional
corridor for east-west commuters as it
prestressed precast beams can then be
connects the East Coast Park Expressway
launched upon the new extended structure.
(ECP) and AYE. Both the ECP and AYE had
For this, a combination of utilizing two
been upgraded over the years into major
existing spare PT ducts and installation of
dual four or five lane expressways, whereas
new PT bars was proposed.
the Keppel Viaduct was still only carrying a
To allow the existing crossbeams to carry
dual three lane carriageway. So, when the
the extra loads, new secondary crossbeams
Land Transport Authority (LTA) finalized the
are to be constructed immediately beneath
plan to re-route the ECP-AYE connection
four of the existing eight beams. The new
with a new expressway – the Marina Coastal
crossbeams are 25m in length, with a
Expressway (MCE) – a study was carried
cantilevered arm of 9m. For this element
out to look into the bottleneck caused by the
of the work, a total of 10 post-tensioning
Keppel Viaduct. While the LTA’s objective to
tendons have been proposed, each having
upgrade the dual three lane carriageway into
38 strands of 12.9mm diameter and each
a dual four lane carriageway looked simple
tendon will ultimately have to be stressed
on paper, the live traffic environment and
to 5,320kN. ➤
major challenge.”
1 Singapore’s Keppel Viaduct, once celebrated
for being the longest in the country, had
become a bottleneck on the busy east-west
commuter route.
2 Site conditions and constraints dictated the
use of a T-shaped cantilevered steel truss
tower, designed in modular segments, for
construction of the crossbeams.
3 The completed crossbeams of the Keppel
Viaduct, extended to accommodate an
additional three or four longitudinal beams,
alongside the eight currently existing beams.
limitations imposed by existing structures
made both the design and construction a
major challenge.
Design concept
Singapore Piling & Civil Engineering
(SPACE), one of our sister companies
within BBR Holdings Limited, was awarded
the design and build contract by the LTA in
February 2011. SPACE drafted in an equally
well-established consultant on vehicular
bridge design – YWL Engineering – and the
first task on hand was to finalize the design
concept for the major upgrading works.
The existing crossbeams are to be extended
to accommodate an additional three or
four longitudinal beams, alongside the
eight currently existing beams. To achieve
this, the designer proposed an additional
crossbeam, extension to the existing
crossbeam, new columns sandwiching
the existing one, plus the pile-cap resting
above the existing pile-cap with new
foundation pipes. With this design concept,
the proposed structure will be able to
accommodate additional longitudinal
beams and the structural capacity of the
viaduct will be enhanced.
2
PORTFOLIO BRIDGES
“The nature and
location of the
Substructures
Construction challenges
To support the entire proposed
The nature and location of the scheme
superstructure, a system of foundational
have brought some very specific challenges
substructures must be designed and
to the project team. The existing buildings
constructed. Firstly, bored micropiles of
and structures, high volume of pedestrian
350mm diameter were proposed as the
footpaths and at-grade traffic carriageways
foundation system due to existing
and junctions have meant that on-site
headroom limitations – the existing
materials storage and extensive scaffolding
headroom clearance of 10m does not allow
are not possible. In such situations, rebar
the deployment of standard bored-piling
and system formwork structures are often
rigs and service cranes. Furthermore,
prefabricated off-site and then installed
micropiling rigs are much smaller and are
on site at night, with road closures for
more applicable for installation of piles
subsequent concrete pouring. Also, the
right beside busy vehicular carriageways
vertical working spaces are constrained by
and junctions. The new pile-caps, designed
the existing viaduct, so using equipment
as transverse beams across the existing
such as boring rigs or cranes is not an
pile-caps to fit within the existing center
option. Then, of course, there is a high
median, are then constructed and cast
volume of live traffic during the day, both at
in-situ on site.
viaduct level and at-grade, which makes our
scheme have brought
some very specific
challenges to the
project team.”
available working time very limited indeed.
Columns
In many ways, we are enjoying the
Similarly, to facilitate construction of the
challenges and opportunities to use our
proposed columns in the middle of live
specialized engineering skills – and also
vehicular carriageways on both sides, the
our expertise in logistics – on this major
steel reinforcement bars for the columns
project which we know, when completed
have to be prefabricated into cages, lifted
in February 2015, will be appreciated by
and secured into place, followed by the
the very many people who drive along this
installation of modular steel system
route on a daily basis. ●
formwork. All these activities are being
carried out with the objective of causing
minimal impact to the at-grade road
vehicular traffic.
Crossbeams
To construct the new crossbeams, the
conventional method of erecting falsework
supports, followed by installation of
reinforcement steel bars and formwork
cannot be adopted. This is due to live
vehicular traffic flanking both sides of the
working space, as well as the headroom
constraint below the viaduct restricting
the use of cranes. Hence, a set of system
falsework / formwork was proposed for
this work. This falsework / formwork,
fabricated with structural steel members,
comes in the form of a T-shaped
cantilevered steel truss tower. The system
is designed in modular segments to
facilitate the lifting operation at a more
manageable level for each module. The
modules are lifted, joined and fixed in
place using nut-and-bolt connections.
Lifting points at the viaduct soffit consist
of steel pins and brackets that are fitted
onto the existing beams of the viaduct.
3
TEAM & TECHNOLOGY
Owner – Land Transport Authority of
Singapore (LTA)
Main contractor – Singapore Piling & Civil
Engineering
Civil & structural engineering
consultant – YWL Engineering
Technology – BBR CONA internal
Systems Pte. Ltd (Singapore)
PORTFOLIO BRIDGES
PENANG SECOND CROSSING, MALAYSIA
Precast segment production
100 DAYS AHEAD
OF SCHEDULE!
BBR Malaysia was contracted
The Penang Second Crossing provides an
Completed segments were delivered by
to carry out match-casting of
additional access bridge to the island of
gantry crane to the barges. The weight of a
Penang which should reduce the high
typical segment was 80t – while individual
traffic volume on the existing bridge.
pier segments weighed in at 110t. The
Second Crossing bridge project
The new crossing consists of two bridges
segments were delivered to the working
and completed their task over
– one for traffic going towards the island
fronts using launching gantries, as the
three months ahead of schedule!
and the other for traffic heading for the
bridge was being erected by the span-by-
mainland. Each bridge consists of precast
span method.
box girder segments with external post-
BBR Malaysia was one of three segment
tensioning. In total, 8,092 segments were
precasters contracted for the task.
needed for the new 24km bridge.
Segment casting was completed 100
Typical segment dimensions are 14m wide
days ahead of schedule – allowing main
by 4m long by 3.2m deep. By casting against
contractor, UEM Builders(M) Sdn Bhd, to
the previously cast segment, the joint
stay well on track with their program. ●
precast segments for the Penang
Chee Cheong Chang of BBR
Malaysia outlines the project.
matching of shear keys during segment
erection can be assured. The other joint
surface was formed by a steel bulkhead.
The tendon sizes are 19 to 31 strands of
15.2mm diameter. Deviator holes in the
deviator segments were formed using
reusable formers. For tighter curves, bent
steel pipes cast into the concrete are used
to deflect the external tendons.
TEAM & TECHNOLOGY
Owner – Public Works Ministry of Malaysia
Main contractor – UEM Builders (M) Sdn Bhd
Technology – Span-by-span precast,
BBR CONA external
PORTFOLIO BRIDGES
SEAFORD RAIL BRIDGE, ADELAIDE, SOUTH AUSTRALIA
World’s third longest incrementally launched bridge
EXTRAORDINARY
ENGINEERING FEAT
When two teams of specialist engineers met – suspended above a river
valley midway across a bridge spanning well over a kilometer in length
– it marked the climax of an extraordinary engineering feat.
The new rail bridge spanned the
bridge in Australia and the third longest
Onkaparinga River and its floodplain,
in the world.
linking two crews who, 20 months
The rail bridge is the key feature in the
previously, had started constructing
5.7km long passenger railway line
different sections of bridge at either end
extension from Noarlunga to Seaford, a
of the project. When the two crews shook
southern suburb on the outskirts of
hands in celebration, they could look back
Adelaide. It was commissioned by the
on a unique civil engineering project that
South Australian Government under a joint
had crossed the large river valley creating
venture arrangement with Thiess MacDow,
the longest incrementally launched
with Structural Systems in support.
2
1
PORTFOLIO BRIDGES
Construction sequence
In order to accomplish the task, Structural
Systems and the contractor’s team
constructed 22 spans of up to 2.3m in
length, cast in steel formwork established
at either end of the bridge, then jacked
progressively into place. A total of 48
segments, mainly 26.15m long were
built this way and pushed using
Structural Systems’ specialist bridge
launching technology.
Although the bridge was launched
continuously from each end, it was
temporarily configured as twin structures,
later to be released to form seven
non-linked sections. This was so that the
railway line would have the ability to
expand or contract with temperature
changes and thereby avoid buckling.
Engineering Excellence commendation
Seaford Rail Bridge has been described
as one of the most impressive civil
construction feats ever undertaken in
South Australia. The mammoth 1,123.9m
long structure has received an Engineering
Excellence commendation. Structural
Systems significant contribution to the
bridge’s concept and construction
methodology was likewise recognized,
noting the minimal impact on the
environmentally sensitive floodplain. ●
3
TEAM & TECHNOLOGY
1 The new Seaford Rail Bridge is the key
feature in a 5.7km long passenger railway
line extension from Noarlunga to Seaford,
South Australia.
2 A total of 48 precast segments, mainly
26.15m long were constructed on site and
pushed into place using Structural Systems’
specialist bridge launching technology.
3 The segments were post-tensioned using
BBR VT CONA CMI internal, BBR VT CONA
CME external and PT Bars.
Owner – Government of South Australia,
Department for Transport, Energy and
Infrastructure
Main contractor – Thiess McConnell
Dowell Joint Venture
Designer – Aurecon
Technology – BBR VT CONA CMI internal,
BBR VT CONA CME external, PT Bar
system, Launching
PORTFOLIO BRIDGES
PUSENCI FLYOVER, SLOVENIA
Post-tensioning and heavy lifting technology
ABOVE AND
BELOW THE LINE
SOLUTIONS
A new flyover has been constructed
over railway tracks, allowing traffic
to pass above the main line from
Ormoz and the old railway crossing
ramp to be closed. In a two-part
project, BBR Adria has posttensioned a 183m long flyover and
also slid a pedestrian underpass
into place – and only a two day
railway possession was required.
Construction of the flyover was completed
in seven segments – the first, at 37m, was
the longest while the remainder were
between 21.4 and 29.4m in length. The
flyover has eight piers with spans from 15
to 25m long.
Within the same project, a pedestrian subway
was also built under the railway tracks next
to the flyover. Railway traffic continued
during construction and only a two day
possession of the tracks was permitted,
so the pedestrian subway was fully
constructed to one side and slid into place.
During the possession, the rails above the
final location for the subway were removed,
excavation was completed and then the
finished underpass was slid into place using
PT jacks. When the subway was finally
positioned, new tracks were installed above
and the railway traffic recommenced. ●
1
1 The 183m long flyover across the main railway
line was completed in seven segments.
2 The new underpass was slid into place using
PT jacks during a railway possession.
TEAM & TECHNOLOGY
Client – Direction for Roads, Republic
of Slovenia
Main contractor – SGP Pomgrad –
Gradnje d.o.o.
Designer – KO-BIRO d.o.o., Maribor,
Slovenia
sliding
BBR Network Member – BBR Adria d.o.o.
(Croatia)
2
PORTFOLIO BRIDGES
PEDESTRIAN BRIDGE, LESOTHO
The award of this specialist works contract
Stressing & anchoring technology
followed earlier post-tensioning services
provided by Structural Systems Africa to
the main contractor and involving 24 x 20m
SPECTACULAR
STRESSED
RIBBON BRIDGE
long post-tensioned precast beams for a
six span bridge, about 30km away.
The two-span stressed ribbon bridge in
Lesotho consists of two groups of sagging
tensioned strands – 25 x 15.7mm strands
each – which follow a catenary arc from
abutment to a central pier to abutment.
These two groups of strands – or ‘bearer
tendons’ – are used to suspend 84 precast
concrete segments which form the concrete
deck. The deck is wafer thin when looked at
in comparison to the maximum 127.75m
span, and is assembled by individually
suspending the 2.5m long precast
segments on the bearer tendons at the
abutment and then shifting them along to
their final position. The bearer tendons were
tensioned to 42% of Minimum Breaking
Load (MBL) before installation of the
segments. Their load was then fine-tuned
to achieve similar levels in both spans.
Each group of 25 strands was made up
of 2 x 8-strand and 1 x 9-strand BBR VT
CONA CMI tendons to enable the fine-tuning
to be carried out on multiple strands at a
time, using 300t multistrand jacks.
Prior to encasing the bearer tendons in
permanent in-situ concrete, additional
2 x 8-strand post-tensioned tendons
were installed for stressing after the
in-situ concrete reached the required
compressive strength. The tendons were
1
248m long and required stressing from
both ends to compensate for wobble effects
and friction losses.
Lesotho is a landlocked country –
In addition to the bearer and post-tensioned
completely surrounded by
tendons, the two abutments required
neighboring South Africa – and is
1 Two long groups of sagging tensioned strands
– or ‘bearer tendons’ – are used to suspend
the 84 precast concrete segments forming
the wafer-thin concrete bridge deck.
TEAM & TECHNOLOGY
Owner – Metalong Authority & Kingdom
of Lesotho
Main contractor – EXR Construction
Lesotho (Pty) Ltd
Designer – SSI in association with Jeffares
& Green, GWC and DHV
BBR VT CONA CMG ground
Systems Africa Ltd (South Africa)
anchoring into the surrounding rock to
enable the suspension of the large spans.
now the home to a unique stressed
SSA was also engaged in the preliminary
ribbon pedestrian bridge. Sean
works which involved the installation of 12 x
Kelly of Structural Systems Africa
22-strand permanent ground anchors. This
Limited (SSA) explains that the
was the first ground anchoring job in Africa
for SSA and, with the help of Structural
248.5m long bridge has been
Systems (Civil) in Australia, a high quality
constructed over a gorge which is
product was achieved. The anchors have a
up to 50m deep and 240m wide.
MBL of 6,138kN and were proof loaded to
When the dam being built
75% of this load, before locking-off at 55%
MBL. With a bond length of six meters and
downstream is commissioned,
free length of 10m, the anchors were
the tail water level will completely
assembled on site and lowered into the
encase the gorge from abutment-
drill hole by a crane. To ensure an even
to-abutment – and, without this
build-up of stresses in each anchor set,
the load in the anchors was increased in
new bridge, it would be impassable
20% MBL increments sequentially, from
by local people.
the inner anchors to outer anchors. ●
PORTFOLIO BRIDGES
1
BOTLEK CORRIDOR, ROTTERDAM, NETHERLANDS
Post-tensioning for bridges, ballast blocks & pergola beams
EUROPE’S LARGEST
LIFT BRIDGE
Europe’s biggest port, at Rotterdam, continues to expand and infrastructure
is being extended and upgraded to meet the future needs of this busy port
and industrial complex. The A15 motorway, giving east-west access across
the country and beyond, is now being extended and Ron van Dijk of
Netherlands-based BBR Network Member, Spanstaal – Ballast Nedam Infra
Specialiteiten B.V., describes his company’s work in the Botlek Corridor –
including how an important element of this €1.5 billion project, the existing
Botlek Bridge, will be replaced by a new bridge which, when completed, will
be one of the largest lift bridges in the world.
FACTS & FIGURES
Pergola construction
– 924 x ø47 PT bar
– 202 x BBR VT CONA CMI 2706
tendons
– 260t prestressing steel
– 72 x elastomeric blocks
(ø350 x 85 and ø850 x 157)
Western access ramp
– 176 x BBR VT CONA CMI 1906
tendons
Bridge counterweights
– 72 x BBR VT CONA CMI 1906 tendons
A major shipping bottleneck will be relieved
bridge, will have two openings for shipping
by the realization of the new lift bridge at
– each around 90m wide and sitting around
Botlek, which is being constructed by the
14m above the river. The headroom above
A-Lanes A15 consortium – formed by
the river will be twice the height of that
Ballast Nedam, John Laing, Strabag and
afforded by the current bridge – thus, larger
Strukton – who are responsible for the
vessels will be able to pass underneath
expansion and subsequent maintenance
without holding up traffic traversing the
of the A15 between the Maasvlakte and
bridge. Its two sections will also allow ships
Vaanplein junction. The project is being
coming from opposite directions to pass
carried out as a ‘Design, Construct and
simultaneously. When completed, the new
Maintain’ contract with a term of 25 years,
Botlek Bridge will be capable of being raised
thus quality and lifetime considerations are
31m in a very short time.
of prime importance.
Spanstaal, in conjunction with Tensa, has
The current Botlek Bridge is mainly used
been working on the adjacent structures,
by hazardous freight which is not permitted
including the western access ramp (long
to pass through the Botlek Tunnel. The new
spans), pergola beams and trough bridges
bridge, being built alongside the existing
(short spans).
PORTFOLIO BRIDGES
2
3
Western access ramp
Three access ramps have been built on both
sides of the Botlek Bridge. The two outer
ones for through-traffic and the middle one
for the access ramp. The ramps were built
in three phases and one of the most notable
features of the post-tensioning here is that
we executed it using couplers. In the
execution of this part of the project, we
used 176 BBR VT CONA CMI tendons and
280t of prestressing steel.
On the east side of these long spans are four
trough bridges each 37m long and posttensioned with 12 x 2206 strand tendons.
4
Pergola construction
Traffic on the Botlek Bridge will cross the
Counterweights
traffic exiting the Botlek Tunnel. Thus,
The new bridge will be the biggest lift bridge
pergola structures, made of prefabricated
in Europe and, therefore, very heavy ballast
I-beams, are being built to connect the new
blocks are needed – the two steel bridge
bridge over the tunnel entrance ramps to
decks weigh 7,200t. The four 2.5t blocks –
the A15.
two for each bridge deck – will each be post-
During one weekend, we lifted and installed
tensioned with 18 CONA CMI tendons. Nine
the 36 prefabricated 37-48m long, 2.8m
tendons will be secured, using CONA CMI SP
high I-beams – weighing up to 238t each –
anchors, to the steel plates on two opposite
into their final locations where they rest
sides at the base of each block.
on 72 elastomeric blocks. The beams are
linked together by two rods and the gaps
Specialist works
between the beams were filled with grout.
Spanstaal is also responsible for specialist
After every two beams had become
works involved in the construction of various
completely monolithic with each other, the
other access bridges on the Botlek Corridor,
beams were post-tensioned using 10 to 12
some of which has involved the supply of
CONA CMI tendons per grid. Then we
900 elastomeric blocks with epoxy and the
grouted all the transverse tendons with a
production and installation of 600m of
special grout mixture.
expansion joints.
All of this work had to be carried out above
When the new bridge is commissioned in
live traffic. For this, we used three dense
early 2016, demolition of the old bridge will
scaffolding grids hung from the tunnel walls
begin and finally the flow of both shipping
so as not to impede the traffic flow beneath.
and road traffic will be eased. ●
1 Pergola structures, made of prefabricated
I-beams, are being built to connect the new
bridge over the tunnel entrance ramps to
the A15.
2 Botlek Bridge, Western Access Ramp, long
spans – continuous post-tensioning tendons
are placed on the deck near the construction
joint, coupling cables have been stressed.
3 The precast prestressed I-beams for the
pergola structures – each beam weighing
up to 238t – were post-tensioned using
10 to 12 BBR VT CONA CMI tendons per grid.
4 The two steel decks of the new lift bridge
weigh 7,200t and require four 2.5t posttensioned ballast blocks.
TEAM & TECHNOLOGY
Owner – Rijkswaterstaat
Main contractor – A-Lanes A15
Consortium (Ballast Nedam, John Laing,
Strabag & Strukton)
PT bar, Bearings, Expansion joints
BBR Network Member – Spanstaal –
Ballast Nedam Infra Specialiteiten B.V.
PORTFOLIO BRIDGES
BATINAH EXPRESSWAY, SULTANATE OF OMAN
Testing & post-tensioning works
The Batinah Expressway Package-1
project for the Ministry of Transport and
Communication (MOTC) is the first
significant bridge project – involving nearly
LONGEST
BRIDGE
TENDONS
IN OMAN
1,400t of prestressing steel – secured by
Structural Systems in Oman.
Extensive testing, comprising of both static
load and load transfer tests, was
undertaken in accordance with project
specifications to demonstrate the
compliance of the BBR VT CONA CMI
systems to the requirements of AASHTO
LRFD Bridge Construction specification for
highly aggressive environments. For further
details, see Page 68.
The Barka Interchange, forming part of the
Batinah Expressway Package-1 project, is
located at Barka near to Muscat. It has two
structures – the East Bridge and the West
Bridge. The length of each bridge is 160m
over three continuous spans. The center
Since Structural Systems began operations in the Middle
span is 70m and both end spans are 45m
East, the team has provided technology and expertise
each. Each bridge is a three cell post-
for the post-tensioning of over 50 bridges in the region.
tensioned box girder structure, with depth
Now, they are working on a major bridge project in
Oman, Warwick Ironmonger takes up the story.
varying from 2m to 4m.
For the Barka Interchange, we used the
BBR VT CONA CMI 4206 post-tensioning
system and almost 260t of prestressing
steel. The interchange is believed to feature
the longest single bridge tendons – around
162m long – in Oman.
With these significant bridges now under
their belt, Structural Systems have now
managed to secure further bridges works
in Oman including the Murray to Al Ayn
Bridges and the Al Jazeera Bridges at Sur,
both with MOTC, and the Oman Convention
and Exhibition Center civil works for
OMRAN, the company set up by the
Government of Oman to deliver major
projects and to manage assets and
investments of the tourism sector. ●
1
1 For the Batinah Expressway’s Barka
Interchange project, BBR VT CONA CMI
post-tensioning systems were tested to
demonstrate compliance with the
requirements of AASHTO LRFD Bridge
Construction specification for highly
aggressive environments.
2 The 162m long post-tensioning tendons used
on the project are believed to be the longest
single bridge tendons ever used in Oman.
TEAM & TECHNOLOGY
Owner – Ministry of Transport &
Communication
Main contractor – Galfar
Consultant – Parsons
Systems Limited (Oman Branch)
2
PORTFOLIO BUILDINGS
POST-TENSIONED SLAB & BEAM SOLUTIONS, POLAND
Optimizing structures with versatility and strength
EARLY INVOLVEMENT
FOR BEST SOLUTION
Structures, such as the new Business Garden offices in Warsaw, owe
much to the expertise and ingenuity of BBR Polska’s dedicated team of
engineers who are focused on developing and applying leading-edge
post-tensioning solutions for buildings. Bartosz Lukijaniuk, Design
Coordinator, of BBR Polska talks us through some recent projects
which have offered clients and their main contractors some real benefits.
1
The new Business Garden office
The BBR Polska team had to meet a
complex in Warsaw consists of two
number of challenges. There were long
buildings – a further five buildings will be
spans of up to 11.4m and some difficult
constructed in a second phase. The complex
architectural shapes – most of the slabs
features post-tensioned slabs throughout –
were unique. We were also targeting low
even in the underground car park – and
material consumption rates and, for a
these cover a total area of 52,000m2. We
typical slab, mild steel consumption was
used the BBR VT CONA CMM unbonded
around just 11kg/m2.
system which best suited the project needs.
Without doubt, our early involvement in
the project – right from the conceptual
design stage – helped to deliver exactly
what the client wanted. ➤
1
PORTFOLIO BUILDINGS
2 Structural optimization
3 Achieving long cantilevers
“Where longer spans
Another example of a building for which
The architect’s vision for a new luxury
are designed by
we adopted an unbonded post-tensioning
residential development in Warsaw
approach to the slabs can be found in the
included the construction of balconies
architects, post-tensioned
public sector – at Warsaw Medical
with long cantilevers of up to 4.6m –
beams are the ideal
University.
uneconomical to design using only
For this project, post-tensioning technology
reinforced concrete. Again, we were
solution for minimizing
was chosen as an alternative solution to
brought into the project team from the
beam size – and also
the original design which used reinforced
earliest concept stage and were thus able
concrete slabs with void forming ‘plastic
to offer advice on a structural solution to
construction costs.”
bubbles’ to make the slabs lighter. With
fulfill the architectural vision. Slabs were
our CONA CMM post-tensioned solution,
post-tensioned with BBR VT CONA CMM
the 2,800m2 of slabs were not only thinner
unbonded post-tensioning tendons.
but consumption of mild reinforcement
was much lower.
4 Reduced materials consumption
Here, we joined the project team with the
Meanwhile, in Wroclaw, the structural
express purpose of bringing our ideas for
solution for part of a multi-purpose building
optimizing the structure to the table.
generated spans of around 10m – a one
span slab with a small cantilevered balcony.
With our help, the use of flat bonded
BBR VT CONA CMF post-tensioning tendons
within a 350mm thick slab was chosen as
the best solution for this structure. An
additional advantage offered by our solution
was low consumption of mild reinforcement
– at a rate of only around 6kg/m2.
2
3
4
PORTFOLIO BUILDINGS
TEAM & TECHNOLOGY
1 Business Garden, Warsaw
Owner – Wi´niowy
Office Park / Swede
s
Center
Main contractor – Hochtief Polska
Architect – APMD
Designer – ARCADE Polska (structural),
SDS & BBR Polska (post-tensioning)
Technology – BBR VT CONA CMM
monostrand
BBR Network Member – BBR Polska
Sp. z o.o. (Poland)
2 Medical University, Warsaw
5
Owner – Medical University, Warsaw
Main contractor – Budimex S.A.
Architect – Kontrapunkt V-projekt
Designer – Kontrapunkt V-projekt
(structural), POMOST & BBR Polska
(post-tensioning)
monostrand
Sp. z o.o. (Poland)
1 Business Garden offices, Warsaw – long
spans and complex architectural shapes, as
well as low material consumption rates were
achieved through early project involvement
and the post-tensioning expertise of the
BBR Polska team.
2 Warsaw Medical University – another early
involvement project where our alternative
post-tensioned approach to construction
produced thinner slabs and a lower
consumption of mild reinforcement.
3 Residential building, Warsaw – with early
advice and BBR VT CONA CMM posttensioning, we helped to fulfill the architect’s
vision for this new luxury development.
4 Multi-purpose building, Wroclaw – flat
bonded BBR VT CONA CMF post-tensioning
was used to produce one span slabs with
small cantilevered balconies.
5 Korona Kielce shopping center – beams
post-tensioned using the BBR VT CONA CMI
bonded system were constructed for the
main access footbridge.
6 Silesian Museum, Katowice – BBR VT CONA
CMI and CMM post-tensioning technology
was chosen here to minimize the beam size
over the main two level exhibition halls and
three levels of underground parking.
3 Residential building, Warsaw
Owner – Dom Development
Main contractor – Eiffage Polska
Budownictwo
Architect – Maka.sojka.architekci
Designer – ARBO (structural), SDS &
BBR Polska (post-tensioning)
monostrand
Sp. z o.o. (Poland)
4 Multipurpose building, Wroclaw
Owner – Wisher Enterprise
Main contractor – Karmar S.A
Architect – Mackow Pracownia
Projektowa
Designer – PB Stalbet (structural),
SDS & BBR Polska (post-tensioning)
Technology – BBR VT CONA CMF flat
Sp. z o.o. (Poland)
6
5 Korona Kielce shopping center, Kielce
5 6 PT beams make clear spaces
CMM post-tensioning technology was
Where longer spans are designed by
chosen to minimize the beam size.
architects, post-tensioned beams are the
Post-tensioned beams were designed and
ideal solution for minimizing beam size –
installed over the main two level exhibition
and also construction costs. One such
halls and three levels of underground
example of a PT beam solution was
parking. The beams over the exhibition
executed by BBR Polska for a shopping
halls are about 25m long – one span with
center in the city of Kielce. BBR VT CONA
a 3m cantilever – while the parking slab
CMI post-tensioned beams were used in
beams are 32m long and create two spans.
the footbridge forming the main access to
No matter what the purpose of the
the shopping center. The BBR Polska team
building, the use of a post-tensioned
offered a solution based on BBR VT CONA
approach to construction can help to
CMI bonded post-tensioning with
create great usable space, fulfill
multistrand tendons.
architectural visions and optimize both
Another interesting example showing the
materials and costs. The team at BBR
benefits of post-tensioning for long beams
Polska has enjoyed these challenges and
with heavy load capacity was at the Silesian
stands ready for even more challenging
Museum in Katowice where CONA CMI and
early stage involvement projects. ●
Owner – Church Land Development
Main contractor – SPS Construction
Sp. z o.o.
Architect – Bose International Planning
& Architecture
Designer – Bartels Polska & Chodor
Projekt (structural), K2 Engineering &
BBR Polska (post-tensioning)
Technology – BBR VT CONA CMI
internal
Sp. z o.o. (Poland)
6 Silesian Museum, Katowice
Owner – Silesian Museum
Architect – Riegler Riewe Archtekten
Designer – Firma Inzynierska
STATYK (structural), SDS & BBR
(post-tensioning)
internal, BBR VT CONA CMM
monostrand
Sp. z o.o. (Poland)
PORTFOLIO BUILDINGS
1
2
PUBLIC CAR PARK, VARAZDIN, CROATIA
Famed for its baroque architecture,
Post-tensioning creates large spans
Varazdin in northern Croatia has
long been a major center for tourism
LARGE SPANS
ENHANCE
UNDERGROUND
PARKING
and commerce. It is here, below
Kapucin Square, recounts Kresimir
Bogadi of BBR Adria, that an
acclaimed new 443-space
underground city center car park
has been created.
Close to Varazdin Park, the railway station
and all the City’s major attractions, the new
underground garage has two below grade
levels with a total area of 12,370m2 which
have been designed in a 77m by 80m layout.
At five meter intervals, there are beams
running across five column spans 16m each.
The lower slab will only be loaded with traffic
and was designed as a 160mm slab with
500 x 600mm beams laid in one direction
at five meter intervals. However, the upper
slab has to carry greater load (33.5kN/m2)
and was therefore designed as a 240mm
thick slab with 750 x 900mm beams.
Tendons in the greater span direction are
located inside the beams, while in the
perpendicular direction they are located in
the slab.
The overall quality and comfortable parking
experience afforded is an advantage of
being able to remove the middle columns
in the 16m span direction, through the
adoption of a post-tensioned approach.
TEAM & TECHNOLOGY
Client – Crtorad d.o.o.
Main contractor – Zagorje Tehnobeton d.d.
Designer – K.A. Biro d.o.o.
monostrand
(Croatia)
3
PORTFOLIO BUILDINGS
Optimal solution
There are several reasons that unbonded
post-tensioning was chosen as the
UNDERGROUND CAR PARK, WROCLAW, SILESIA, POLAND
Material & cost savings with post-tensioning
optimum solution for this project. Firstly,
there was positive experience in terms of
bridging these spans from the Tuskanac
underground car park in Zagreb – a project
carried out by BBR Adria in 2008.
Next, the high water table demanded shallow
excavation – and consequently, construction
could only be carried out with shallow slabs.
The third reason was the time schedule –
project execution during the winter, with a
tight time schedule, dictated use of 15 x 80m
working segments. Thus, in the direction
of span beams, a 15 x 80m slab was
OPTIMIZED
CONSTRUCTION
& BUDGET
concreted and stressed in one go – thanks
to unbonded technology, the friction losses
could be kept to a minimum.
Only the first slab above foundation level
was subsequently connected with the side
walls after stressing, while the upper slab
was cast and stressed along with the side
walls. This approach resulted in an absence
of shrinkage and temperature cracks,
despite a large segment length of 80m.
Above the car park’s upper slab, on top of a
one meter bank layer, a decorative city
square was constructed and landscaped.
BBR Network Member, BBR Polska has recently been involved in a
project which clearly highlights the benefits of early collaboration
Safe, easy and attractive to use
between main and specialist contractors and shows how PT technology
The new car park is characterized by its
used in slabs saves construction materials and allows optimization of
great all-round visibility – with only minimal
visual barriers – which, together with the
other structural elements. Design Co-ordinator, Bartosz Lukijaniuk,
wide access ramps and their gentle
outlines the realization of this important new underground car park right
gradients, make this new facility safe, easy
next door to Wroclaw’s Centennial Hall.
and attractive to use.
As a result of the positive feedback from
The underground car park is designed for
Our post-tensioned slab solution saved
investors and clients, BBR Adria is strongly
around 800 cars, over two underground
12% of the construction costs compared
promoting this large span approach to
levels, and covers a total area of
with traditional reinforced concrete.
building layout as a standard ‘way to go’
7,200m2 – with some 12,700m2 of post-
In addition, our solution minimized the
in the region. Meanwhile, the quality and
tensioned slab.
overall structural thickness – which was
optimal solution offered by this type of
Our early selection by the main contractor
actually a crucial issue. By using our PT
building have officially been recognized by
meant we could contribute to concept
solution, we reduced the overall height
the civil engineering profession – the
design and project specification. The main
of the structure by 700mm – again,
project’s designers were presented with
contract includes design, construction
compared with taking a traditional
the 2013 ’Kolos’ Award by the Croatian
and maintenance of the car park for
reinforced concrete approach. This
Chamber of Civil Engineers for a remarkable
several years – so our client was
structural optimization reduced
achievement in the construction category. ●
especially keen to use structural solutions
excavation needs by about 5,000m3 too. ●
and technologies offering problem-free
maintenance. The client chose BBR
technology because, among other
1 Installation of BBR VT CONA CMM
monostrand unbonded post-tensioning
underway – this system was chosen as there
was good earlier experience locally and the
system promoted a particularly fast
construction time.
2 Post-tensioning allowed the creation of large
spans at the new city center underground
car park in Varazdin, Croatia.
3 Adopting a post-tensioned approach allowed
removal of middle columns in the 16m span
direction – and affords an overall quality and
comfortable parking experience.
benefits, post-tensioning promotes
TEAM & TECHNOLOGY
reliable slab performance – especially in
Owner – Hala Ludowa
Designer – VROA Architekci and CH+
Architekci (architectural), Bartels
Polska (structural), POMOST & BBR
(post-tensioning)
monostrand
Sp. z o.o. (Poland)
relation to reduced cracking.
Also, our solution offered low construction
material consumption. The rate of
consumption of reinforced concrete was
12kg/m2 and for post-tensioning this was
reduced to 3.5kg/m2 with a slab thickness
of 250mm for spans of 7.85 x 7.85m.
PORTFOLIO BUILDINGS
PROJECT HIGHLIGHTS
Brief overview of five BBR Network projects in Singapore
SPACIOUS AND STRONG
IN SINGAPORE
With space always at a premium on the island of Singapore, it is no surprise
that owners, developers and users of buildings of all types are keen to
embrace the benefits of post-tensioning. Five recent schemes here
demonstrate the advantages of post-tensioned beams and slabs, not only
for delivering greater floor-to-ceiling heights, but also higher floor loadings
– and maximized opportunities for expansive column-free spaces.
3 Eldix @ Sungei Kadut Planning Area
TEAM & TECHNOLOGY
This 12-storey ramp-up – featuring a
delivery ramp – multi-user industrial
1 Owner – Singapore Workforce
Development Agency (WDA)
Main contractor – Greatearth
Construction Pte. Ltd
C&S Consultants – Beca Carter
Hollings & Ferner (SE Asia) Pte. Ltd
Technology – BBR CONA internal,
BBR CONA flat
BBR Network Member – BBR
Construction Systems Pte. Ltd
(Singapore)
building is located within the Mandai Estate,
northwestern Singapore.
2 Owner – Ministry of Education
Singapore
Main contractor – Hytech Builders
Pte. Ltd
C&S Consultants – Beca Carter
Hollings & Ferner (SE Asia) Pte. Ltd
BBR CONA flat
(Singapore)
3 Owner – EL Development Pte. Ltd
Main contractor – Evan Lim & Co.
Pte. Ltd
C&S Consultants – Fong Consult
Pte. Ltd
BBR CONA flat
(Singapore)
1
National Continuing Education and
4 Premier @ Kaki Bukit
Training (CET) East Campus, Paya Lebar
This is a flexible blend of eight story 'ramp
A newly completed eight storey teaching
up' and nine storey flatted, industrial
facility, the CET Campus East offers
development aimed at expanding and
industry skills training and also provides
aspiring entrepreneurs.
horizontal training programs, covering
By adopting a post-tensioned approach to
employability skills and service excellence.
the scheme, the development offers high
In addition, CET East Campus will also host
ceilings and a column-free layout promoting
short quality CET programs, such as master
better space utilization, as well as allowing
classes, professional development
direct container access for ramp-up units
programs and workshops.
to enhance business efficiency.
4 Owner – Wee Hur (Kaki Bukit) Pte. Ltd.
Main contractor – Wee Hur
Construction Pte. Ltd
C&S Consultants – LSW Consulting
Engineers Pte. Ltd
BBR CONA flat
(Singapore)
5 Owner – Ascendas Pte. Ltd
Main contractor – Nakano (Singapore)
Pte. Ltd
C&S Consultants – Ronnie & Koh
Consultants Pte. Ltd
BBR CONA flat
(Singapore)
2 New Primary School, Bukit Panjang
5 8B @ Admiralty, Admiralty Street
Site 16
This multi user light industrial scheme
Winning the coveted BCA Green Mark
in northern Singapore features eight
Platinum Award, the new school consists of
post-tensioned floor levels offering high
three blocks of five to six storey teaching
floor loadings and excellent ceiling heights,
facilities, one block containing a multi-
as well as dedicated loading bays and
purpose hall – with a rooftop football field –
post-tensioned access ramps for trucks
and other ancillary buildings.
to every floor.
PORTFOLIO BUILDINGS
resulted in the award of post-tensioning
works for this project.
Our role here was to post-tension the
suspended floors, typically of 13.5m x 9m
floor spans involving 300t of prestressing
steel. By adopting a PT approach to the
MUHARRAQ SEEF MALL, BAHRAIN, UNITED ARAB EMIRATES
public areas, wide open spaces have been
achieved which will not only enhance
Post-tensioning for floor slabs
consumer experiences, but will also offer
BAHRAIN’S NEWEST MALL
flexibility should the client require structural
As Bahrain’s new Muharraq Seef
The Muharraq Seef Mall is a BD15.65m
and other specialist services for buildings
Mall opens its doors to the general
project situated between the Muharraq Club
has grown in the region, often as a result
and the Arad Fort in Bahrain, facing onto the
of our first class performance on
newly constructed corniche and bay. The
infrastructure schemes. To date, we have
BBR Network Member, NASA
mall has been constructed over two retail
provided technology and expertise for over
Structural Systems LLC, reflects
floors offering approximately 30,000m2 of
200 buildings, 19 storage tanks and 50
on the challenges presented by
retail space with ample parking underneath
bridges throughout the Middle East. ●
public, Warwick Ironmonger of
this major project – one of many
changes at some later stage.
Our reputation for providing post-tensioning
on the ground floor. The project also
includes an open air amphitheater that will
building projects carried out during
be used for public and cultural events.
the company’s 15 years in the
Previous involvement on similar projects –
Middle East.
including a nearby mall on the Muharraq
Island and the 162,000m2 Bur Juman
Expansion project in Dubai – along with
sound technical support at tender stage,
TEAM & TECHNOLOGY
Owner – Muharraq Mall Company
Main contractor – Almoayyed Contracting
Technology – BBR CONA flat
BBR Network Member – NASA Structural
Systems LLC (United Arab Emirates)
CONCERTO NORTH KIARA CONDOMINIUM, KUALA LUMPUR, MALAYSIA
Post-tensioned transfer slab
WINNING ALTERNATIVE DESIGN
Concerto North Kiara is a new condominium
structural PT slab to the columns. We
consisting of three high rise residential
overcame this problem by increasing the
blocks above a podium containing four car
thickness of the PT slab by 150mm at
parking levels. The unique design –
several locations, making the structure
When time and costs – as well as
resembling a piano keyboard – results in high
stiffer and distributing the loads through
achieving a challenging design
drops in floor level which contribute to the
selected columns. By placing the two-way
complexity in structural design and detailing.
tendons with selected profiles at the
The transfer floor was originally designed
required locations, load balancing between
Construction Systems Malaysia
with a 2,100mm deep beam and slab
the gravity loads and prestressing uplift
produced a contract-winning
system. We redesigned it with a post-
forces was achieved.
alternative design for the client,
tensioned slab to support the load-bearing
While the main contractor is benefitting
shear walls which in turn support 30 floors
from the shallow and simpler formwork
above. A typical post-tensioned slab is
and the shorter erection time, the owner
Chuen Lin Lee, Design Engineer,
1,400mm thick and transfers the loads to
will also benefit from the flat and more
tells the story.
columns on an 8m x 8m grid. Our client, the
attractive soffit of the transfer floor.
main contractor, had secured this project
The post-tensioned slab was designed for
based on the benefits and cost reductions
two stage casting with two groups of 1205
resulting from our alternative design. Time
BBR CONA internal tendons. After first
TEAM & TECHNOLOGY
was critical as the foundations had been
stage concreting had achieved a 35N/mm2
Owner – B C B Berhad
Main contractor – Awangsa Bina Sdn. Bhd.
Prestressing contractor – BBR
Construction Systems Malaysia
Technology – BBR CONA internal
built, while the design using our alternative
strength, the first group of tendons were
post-tensioned slab was still in progress.
stressed to enable the second stage
Various high drops of up to 700mm – for
casting. Thus, the props to support the wet
landscaped gardens – with few column
concrete weight and backprops required for
supports below, made it difficult to achieve
floors below had been halved, providing
the required load transfer through the
savings to the client. ●
concept – were critical, BBR
who was also the main contractor.
PORTFOLIO BUILDINGS
ELEPHANT HOUSE ROOF, ZURICH ZOO, SWITZERLAND
Post-tensioning of ring beam
TRUMPETING
TRIUMPH
The centerpiece of Zurich Zoo’s
The giant roof with an area of 6,000m2 and
additional elements as far as possible.
85m in diameter acts as a self-supporting
The ring beam transfers the roof loads
shell structure, whose loads are transferred
through a limited number of shear walls
via a post-tensioned concrete ring beam to
to the roof foundations which are
house with a striking curved wooden
local roof foundations. The roof's shape is
anchored by piles to resist vertical load
roof structure. Fabian Persch of
irregular in order to have a natural, random
and by permanent ground anchors for
BBR Network Member Stahlton AG
appearance and to meet the building's
horizontal load.
utilization requirements. The 270m long
It is essential for the roof's stability that
ring beam was the most complex element
the shear walls should only permit very
of the support structure. It follows the
small horizontal movements. Thus, each
uneven behavior of the roof edge and,
wall is prestressed with a vertical post-
while bridging spans of up to 40m with
tensioning tendon. To withstand the
only very small deflections permitted, the
design loads, as well as to act as a tension
beam is intended to be thin and invisibly
flange in accidental design situations –
integrated in the roof. This could only be
such as the failure of ground anchors
achieved by using post-tensioning.
and hence the horizontal support of an
The aim of the concrete structure's design
abutment zone – the ring beam itself is
was to integrate all concrete members,
prestressed with nine post-tensioning
such as rain water tanks or stables, for
tendons with lengths of up to 120m and
transferring the roof load – and thus avoid
a prestressing force of 190t per tendon.
2
10,000m Kaeng Krachan Elephant
Park is a circular concrete elephant
reveals the challenges behind the
realization of this unusual structure.
1 Artist’s impression of the finished Elephant
House at Zurich Zoo, Switzerland.
2 Reinforcement and post-tensioning tendons
were installed in a ‘wooden channel’ which
was subsequently closed, filled with selfcompacting concrete and became an integral
part of the structure.
1
PORTFOLIO BUILDINGS
FOUNDATION SLAB FOR STONE CRUSHING BUILDING, LA ROCHELLE, FRANCE
Crack-free post-tensioned ground slab
CRUSHING VICTORY
Holcim France – part of the Swiss group, Holcim Ltd – is constructing a
new finishing and distribution center in south western France. The project,
known as Ciments de La Rochelle, will create a cement manufacturing
and packaging center in the heart of the city’s maritime port. BBR
Network Member, ETIC, was called upon to provide post-tensioning
services for one of the site’s key building complexes. Guillaume Wastiaux,
2
Sales Manager for the French market, takes up the story.
The tendon layout is three-dimensional –
This overall project was conceived to
We supplied and installed horizontal
the cables are arranged so that, vertically,
support the strong growth in construction
post-tensioning using 12 BBR VT CONA
the ring beam lifts the roof in the spans
and public works activities in the west of
CMI BT 2706 tendons and vertical
and, horizontally, it is tied to the wall
France. The new plant will undertake the
post-tensioning with 126 x 50mm
abutments. Two tendons were always
mechanical crushing and mixing of raw
diameter PT bars.
arranged in parallel to avoid twisting of
materials and packaging of the finished
While the PT bars were prefabricated
the ring beam. Due to the sophisticated
product for distribution. When completed,
in the ETIC workshop, we installed the
geometry of the structure, the position
the site will accommodate seven zones –
CONA CMI tendons on site using the
of the tendons and the prestressing
raw material storage silos, raw material
strand-by-strand method and then
niches had to be specified and measured
mixing tower, crushing and drying
stressed and grouted them with cement.
to millimeter accuracy.
complex, cement and hydraulic binder
It took our team just two weeks on site
Reinforcement and post-tensioning
storage silos, packaging building,
to complete the work. ●
tendons were installed in a ‘wooden
storage facility, plus an administration
channel’ that when subsequently closed
building with a laboratory and offices.
with shuttering became a ‘wooden pipe’
Our role has been to provide post-
and was filled with self-compacting
tensioning for the massive 20 x 20 x 10.5m
concrete. The lowest layer of the
post-tensioned floor slab of the crushing
multi-layer wooden roof served as the
building. As the slab will carry the
soffit formwork and, together with the
enormous load of a stone crushing
shuttering and the formwork sides, was
machine – crucial to the plant’s
also left in the structure.
operations – the client naturally
After staged stressing of the tendons,
required an approach which would
the roof – so far supported by falsework
minimize cracking.
TEAM & TECHNOLOGY
Owner – Holcim
Main contractor – ERC HARRANGER
PT bar
BBR Network Member – ETIC S.A. (France)
– was lowered and the loads transferred
to the ring beam and foundations,
respectively. Structural deflections were
monitored with fiber-glass sensors,
such that comparisons could be made
between the calculated and actual
forces / moments in the ring beam. ●
TEAM & TECHNOLOGY
Client – Zurich Zoo
Main contractor – Landolt AG
Designer – Walt + Galmarini
Technology – BBRV wire
BBR Network Member – Stahlton AG
(Switzerland)
PORTFOLIO BUILDINGS
2
1
THE PARABOLA, LONDON, UK
Post-tensioned slab design & installation, specialist heavy lifting techniques
REVIVING A BOLD
STATEMENT
“We are using the
A redevelopment scheme based around a prominent former public
BBR VT CONA CMF
building in Kensington, London will see the revival of an iconic structure,
and CMI 1206 systems
along with the creation of unique museum space and new residential
with both fixed and
movable couplers to
accommodation. Richard Gaskill of local BBR Network Member,
Structural Systems UK Limited, takes us through the project’s history
and outlines the construction challenges.
allow continuity of
pre-stress across the
The Parabola – the former Commonwealth
The planning brief called for the
Institute building – had been neglected for
preservation of the main structure – a
construction joints.”
nearly 10 years before it was acquired by
listed building – for use as an art gallery
developers Chelsfield Partners. Their vision
with a greater integration of the gardens
is to bring life back to the listed building
into Holland Park. After an architectural
which has a quirky saddle-shaped structure
competition to explore the best design
at its heart. The Parabola – accommodating
and practice, much discussion with
The Design Museum – will become the
English Heritage, the local authority and
centerpiece in a development designed to
other parties, planning consent was given
complement the ingenuity that was the
in September 2009 and construction
basis of its original creation.
commenced on site in 2012.
History & planning
PT design & installation
Completed in 1962, on a 3.25 acre site
Structural Systems’ role is to provide
fronting onto Kensington High Street, The
post-tensioning design and installation
Parabola’s copper clad hyperbolic paraboloid
expertise for the floor slabs of the three
roof has been described as a ‘bold
new residential buildings and to apply
statement’ back then. The striking roof was
specialist jacking services techniques for
born of the architect’s desire to create a ‘tent
the support of the iconic roof of The
in the park’ – half of the roof was concrete,
Parabola to enable the existing floors to
whilst the other half was traditionally built.
be demolished and rebuilt beneath it.
1 General view of Block B – PT slabs under
construction using BBR CONA CMF BT 3
and 4 strand tendons.
2 View of parabolic roof structure to Block D,
with post tensioned Block C undergoing
fit-out work in the background.
PORTFOLIO BUILDINGS
AIR FORCE MUSEUM OF NEW ZEALAND, WIGRAM, CHRISTCHURCH
Post-tensioned concrete floors
GROUNDED IN
EXCELLENCE
Growing demand for high-performance post-tensioned concrete floors
continues to keep the BBR Contech team busy. One recent project
required the provision of strong floors with attractive finishes capable
of holding the weight of aircraft on display at the Air Force Museum of
New Zealand.
Levels 1 and 2 of the structure beneath
the roof of the existing Institute (Block D)
are being installed using post-tensioned
concrete, as are the new buildings on the
site – Blocks A, B and C. We are using the
BBR VT CONA CMF and CMI 1206 systems
with both fixed and movable couplers to
allow continuity of pre-stress across the
construction joints.
Supporting the roof
Achieving suitable support for the roof
was logistically and technically difficult.
It required a combination of hydraulic
jacking, flat jacking and bar jacking – in
association with an extremely complex
temporary works solution involving a
considerable amount of steelwork.
The original design of The Parabola
The Museum is home to a superb
Bristol Freighter, with a smooth finish and
incorporated the latest techniques of
collection of military aviation memorabilia,
comfortable ambient temperature to suit
that time and used lightweight
fully restored aircraft, such as the de
the room’s role as a venue for displays
construction to produce a building that
Havilland Vampire, Supermarine Spitfire
and public functions.
was functional with minimal resources.
and P-51 Mustang, to medals and
The second post-tensioned floor, covering
The inclusion of the three apartment
parachute-silk wedding dresses.
983m2, was installed in the workshop
buildings along with The Design Museum
In February 2013, the Museum celebrated
area. Together, these two projects have
will again reflect contemporary
a major milestone – the official opening by
helped the Museum to improve both its
construction techniques and produce a
the Governor-General of a NZ$15 million,
public face and the working environment
scheme which is energy efficient, easy
6,500m2 extension designed by Warren
it provides for those responsible for its
to access and is complemented by its
and Mahoney. The new ‘Technology
fascinating restoration projects. ●
landscaped surroundings. ●
Center’ – which effectively doubles the
Museum’s original size – includes an
elegantly spacious, hangar-styled display
gallery, a large restoration area and a
TEAM & TECHNOLOGY
Owner – Chelsfield Partners
Main contractor – MACE
Architect – OMA
BBR VT CONA CMF flat, Heavy lifting,
PT bar, MRR range
Systems UK Limited (UK)
1
number of workshops.
BBR Contech was involved in two floors in
the Museum. The first was the floor in the
display gallery – a 200mm-thick, 4,200m2
expanse of post-tensioned, water-pipeheated concrete, which was poured in two
consecutive days. The floor has the
strength to hold the 130kN axle load of a
TEAM & TECHNOLOGY
Client – RNZAF Museum Trust Board
Architect – Warren and Mahoney
Main contractor – Mainzeal Property &
Construction
Flooring contractor – Conslab Ltd
Engineer – Alan Reay Consultants
Technology – BBR CONA flat
(New Zealand)
PORTFOLIO STAY CABLES
PRZEMYSL BRIDGE, SOUTHERN POLAND
Official opening by Prime Minister
SYMBOL OF
PROGRESS
The new Przemysl Bridge was opened by Prime Minister
Donald Tusk, on the eve of Polish Independence Day –
and in the full glare of the nation's media.
In his speech, Prime Minister Tusk said:
“The fact that today we are standing
underneath these modern pylons, this
modern bridge is a symbol of the
distance Poland has covered.”
TEAM & TECHNOLOGY
Owner – Local Management of District
Roads, Przemysl
Main contractor – Mota-Engil Central
Europe S.A.
Designer – Promost Consulting
Technology – BBR HiAm CONA stay,
Incremental launching
Sp. z o.o. (Poland)
BBR Polska was represented at the
opening ceremony by CEO Jan Piekarski.
The project featured incremental
launching of the steel bridge deck and
installation of BBR HiAm CONA stay cables.
The bridge, which is part of the Przemysl
Ring Road, will alleviate traffic congestion
in the city center and allow easier access
to the border crossing with Ukraine. ●
NEW ACCESS FOR EUROPEAN SCHOOL, MAMER, LUXEMBOURG
Stay cable technology using stainless steel ducting
FLYING ENTRANCE
FOR SCHOOL
When the stunning new flyover
with its unique geometry at Mamer,
in Luxembourg, was opened in late
2013, peak time commuters and
students alike must have sighed
with relief. Claude Néant of BBR
Network Member, ETIC, provides
some insights into this unusual
and very striking project.
1
The N6 highway between Bertrange and
New flyover
Mamer is one of the main routes into the
The new flyover bridge – with two 66m
city of Luxembourg and is obviously very
spans – carries road traffic on a single
busy during the rush hour. With the arrival
unidirectional carriageway, as well as a
of the new European School, right next door
mixed pedestrian and bicycle track on
to an existing technical high school, extra
a curved radius of 102.25m.
road and pedestrian traffic generated by
The structure consists of two steel
the two schools was set to make traffic
frames connected by struts and a
jams even worse.
reinforced concrete slab, founded on
mass abutments and further supported
1 The new flyover bridge is supported on
mass abutments and two concrete piers on
the outer curve, plus 10 stay cables on the
inner curve.
2 Installation of the five pairs of BBR HiAm
CONA stay cables began at the upper
anchorages, on the inclined free-standing
pylon.
3 A special feature of the design is the stainless
steel ducting for the stay cables, installed
using a cable winch-and-pulley system.
4 Installation of the stay cables at the
lower anchorages, on the outside of the
bridge structure.
Improving traffic flow
by two huge concrete piers on the outer
To improve traffic flow on the N6, relieve
edge of the curve. The inside of the
pressure on a key roundabout and provide
curve is supported by ten stay cables
good private and public transport access to
attached to an inclined free-standing
the schools themselves, new dedicated
steel pylon.
infrastructure leading from the main road to
The steel structure was prefabricated
the schools was commissioned. Key features
off site and delivered to the workface
of this would be an underpass for the
in sections for lifting by crane and
technical high school and a flyover with its
assembly on temporary piers. Stay
distinctive inclined steel pylon and stay cable
cables were installed after the concrete
construction for the new European School.
deck had been poured. ➤
Stay cable system
Our role was to prepare the stainless steel
stay cable ducting tubes on the ground and
to supply, install and tension the BBR HiAm
CONA stay cable system.
A special feature of this structure is that it
was designed with stainless steel ducting
for the stay cables which we installed by
using a cable winch and pulley system.
The stays consist of bundles of 15.7mm
diameter galvanized strand that has been
tested and validated according to BBR
procedures. There were five pairs of stay
cables of between 7-15 parallel strands each
which were individually waxed coated and
sheathed, and further enclosed in stainless
steel stay cable ducting.
We began installing the system from the
top anchors and tensioning point on the
pylon, to the lower anchors on the outside
of the bridge structure.
In total, we used 3,900kg of stay cable
strands and 325m of stainless steel ducting,
plus 16 x 15 strand HiAm CONA anchors
and four 7 strand HiAm CONA anchors.
The entire work was completed with great
collaboration between the Tralux and
ETIC teams – and without any access
difficulties for guests attending the official
opening of the nearby school during the
construction period. ●
2
3
TEAM & TECHNOLOGY
Owner – State of Luxembourg, Ministry of
Sustainable Development & Infrastructure,
Regional Services Division
Architect – BENG
Consulting engineer – Schroeder &
Associates
Main contractor – Tralux Construction
Specialist contractors – Victor Buyck
Steel Construction (steel frame)
Technology – BBR HiAm CONA stay
BBR Network Member – ETIC S.A. (France)
4
PORTFOLIO TANKS & SILOS
ANAEROBIC DIGESTER TANKS, HUNGARY
Band post-tensioning of circular tanks
BUILDING
FOR BIOGAS
BBR Network Member KB Vorspann-
The BBR VT CONA CMM tendons
Technik has recently carried out
consisted of two compacted steel strands
post-tensioning of four digester tanks
with a 165mm2 cross-section and 1,820MPa
for biogas production in North Eastern
stressing steel incorporated in bands.
Hungary. In the city of Miskolc, nearly
A further two 1,700m3 digesters were built
200km north-east of Budapest, two
at a plant in Nyiregyhaza. Here, the tanks –
16m high, 18m diameter post-tensioned
both 18m high and 12m in diameter – were
digester tanks have been constructed.
constructed with 142 BBR VT CONA CMM
monostrand tendons made from 150mm2
cross-section, 1,860MPa stressing steel. ●
1
1 Post-tensioning for the two 1,700m3 digester
tanks in Nyiregyhaza consisted of 142
BBR VT CONA CMM monostrand tendons.
2 The two 16m high, 18m diameter posttensioned digester tanks in Miscolc, Hungary.
TEAM & TECHNOLOGY
1 Biogas Plant, Nyiregyhaza, Hungary
Owner – City of Nyiregyhaza
Main contractor – Monolit – Epszer Kft.
Planner – Nyirseg Konzorcium,
Ke-Viz Zrt.
monostrand
BBR Network Member – KB VorspannTechnik GmbH (Austria)
2 Biogas Plant, Miskolc, Hungary
Owner – City of Miskolc
Main contractor – Colas Alterra zrt.
Designer – Megalit Mernoki Iroda KFT
Technology – BBR VT CONA CMM band
BBR Network Member – KB VorspannTechnik GmbH (Austria)
2
WATER RESERVOIRS, AUSTRALIA & NEW ZEALAND
PT precast concrete and design & construction of PT tanks
IMPROVING
WATER SUPPLY
Members of the BBR Network around the world provide services which are vital to the water industry’s
ability to supply fresh water for growing populations. The long term performance and structural stability
of reservoirs can be greatly enhanced by taking a post-tensioned approach to their construction.
1 Wilmers Road Reservoir, New Zealand –
a structure standing 6m high and measuring
31m in diameter.
2 Mount View Reservoir, Australia – the new
five million liter capacity post-tensioned
concrete reservoir is 28.88m in diameter
and 10.6m high.
1
1
Wilmers Road Reservoir, New Zealand
The Christchurch suburb of Hornby is
a structure standing 6m high and measuring
changing rapidly, largely owing to
31m in diameter. The work involved:
residential and industrial growth that is
• supplying the panel manufacturer with
being encouraged as part of a long-term
TEAM & TECHNOLOGY
1 Client – Stronger Christchurch
Infrastructure Rebuild Team
Main contractor – Downer
Engineer – Opus International
Consultants
internal
(New Zealand)
2 Owner – Hunter Water Corporation
Main contractor – Leed Engineering &
Construction Pty Ltd
Designer – Structural Systems Limited
(Australia)
internal
community plan. The local BBR Network
Member, BBR Contech, has provided
ducting for the tendons, which was cast
into the panels
• once the panels were assembled on site,
post-tensioning for a precast concrete
coupling the ducting and carefully
water tank which will improve water supply
installing the 11 tendons – comprising
to the suburb.
seven 12.7mm strands each – horizontally
Recognizing that the community needed an
in the panels, effectively encircling the
additional water supply, Christchurch City
Council has built a new water supply pump
tank’s circumference
• stressing the tendons to the desired
station in the area. The facility comprises a
load, then grouting them in place.
pumping station and a freshwater holding
The project is now complete, providing
tank, with the latter having a capacity of
the residents and businesses in the area
more than 3.7 million liters.
with a much-improved water supply and a
BBR Contech was called on to provide
structure that, thanks to the use of
post-tensioning services for the precast
post-tensioning technology, can withstand
concrete panels that form the tank wall –
the damaging forces of an earthquake.
ETHANE TANK, PORSGRUNN, NORWAY
Horizontal & vertical tank post-tensioning
2
GEARING UP
FOR GAS
As part of an expansion plan for the
2 Cessnock & Lochinvar Hunter Region,
INEOS site at Rafnes in Norway –
Australia
explains John Taraldsen of BBR
The post-tensioning for two concrete
water tanks has recently been designed
Network Member, KB Spennteknikk
and installed by Australian BBR Network
– the company was hired to provide
Member, Structural Systems.
post-tensioning services for a new
Increased demand led Hunter Water
ethane tank.
Corporation to embark upon a water supply
upgrade for parts of the Hunter Region.
The new tank – along with expanded
Two of the projects within this program were
infrastructure – is being constructed in
the Cessnock Water Supply Upgrade and
an industrial park in Porsgrunn, Norway –
the Maitland North Rothbury Water Supply
approximately 200km from Oslo. The
Upgrade – each of which required the
new facility for INEOS will expand the
design and construction of a new reservoir.
company’s ability to access ethane from
At the Mount View Reservoir, part of the
world markets and secure long term
Cessnock Water Supply Upgrade, a five
competitiveness and jobs at the site.
million liter concrete reservoir was
The main contractor, our client, slipformed
constructed. The new reservoir is 28.88m
the concrete walls of the tank and we
in diameter and 10.6m in height.
were on site during the operation.
Meanwhile, for the Maitland North Rothbury
For the horizontal tendons, we used 204
Water Supply Upgrade project, at Lochinvar,
BBR VT CONA CMI 1206 tendons with
a 10ML tank with a 46.28m diameter base
170t of 15.7mm diameter strand (150mm2,
and 10m high walls 10m was constructed.
1,860MPa). The vertical post-tensioning
Structural Systems provided the detail
is made up of 52 CONA CMI 0406 loop
design for the reservoirs, including post-
tendons and we used 17t of strand.
TEAM & TECHNOLOGY
tensioning services. The design
Standing 32m high with an external
incorporated the use of a post-tensioned
diameter of 45.7m, the new tank will be
slab on ground, vertical precast panels for
capable of holding 30,000m3 of ethane and
the walls with post-tensioning both vertically
will be ready to receive its first consignment
and circumferentially.
in the second quarter of 2015. ●
Owner – INEOS / Noretyl
Client – Veidekke Entreprenør AS
Designer – TGE Gas Engineering GmbH
BBR Network Member – Spennteknikk AS
(Norway)
The slabs on ground consisted of a 150mm
thick concrete slab connected to a 600mm
deep x 2000mm wide ring beam. Precast
panels were cast on site and lifted into
position. The panels were 280mm thick
varying in width from 3300mm to
4100mm – and weighing up to 28t.
Individual panels were joined with
circumferential post-tensioning tendons
stitched together by a cast in-situ concrete
infill joint. Due to program constraints the
reservoirs were constructed concurrently
and successfully completed on time and
within budget. ●
PORTFOLIO SPECIAL APPLICATIONS
BRIDGE SLIDING, WESTERN AUSTRALIA
Development & execution of specialist bridge slide operation
SLIDING WITH
SAFETY & SPEED
A bridge sliding operation carried out in connection with a regional railway
link project admirably demonstrates the care, skill and precision with
which the BBR Network delivers customer requirements. Mark Sinclair,
General Manager (Civil Engineering), of Structural Systems – the BBR
Network Member in Australia – recounts how a lateral bridge slide design
and sliding operation was jointly developed with the main contractor for
Package C of the Melbourne Regional Rail Link Project.
1
“The lateral slide method
was chosen to minimize
the impact on rail
traffic as part of the
grade separation works,
thus allowing Anderson
Road traffic to pass
under the rail line.”
2
1 Regional rail link, Melbourne – sliding of the
twin track rail bridge to the rail alignment
during a possession of the tracks.
2 SSL Australia’s site team executed the bridge
slide during three consecutive 12 hour shifts.
Pictured here is the night crew (left to right):
Jeff Babbage, Kennedy David, Alan Denning,
Kane Goodrope and Daniel Reardon – Mark
Sinclair was behind the camera.
3 Two of the three jacks can be seen in this
photo. The isoflow pump and control system
ensured equal hydraulic flow to all jacks
regardless of any load difference, which
ensured constant movement in all locations
and no unexpected loads or movements on
the bridge during sliding.
3
The project involved the lateral sliding of a
A pull back system was designed, detailed
two span, twin track skewed composite rail
and supplied should the need arise to
bridge from its assembly area, to the rail
reverse the bridge, but this was not needed
alignment during a shutdown. The lateral
in this instance, but is a necessary
slide method was chosen to minimize the
insurance considering that launch timing
impact on rail traffic as part of the grade
is always critical.
separation works, thus allowing Anderson
The site works were carried out over three
Road traffic to pass under the rail line.
consecutive 12 hour shifts starting on the
The 45m long, 11m wide, 1,350t bridge was
morning of 7th October 2013. The day
launched laterally using three of our 145t
crew set up and tested the system, then
by 1.4m stroke lifting system jacks and a
the night shift came in to launch the bridge
TEAM & TECHNOLOGY
modular 56mm coupled segmental high
25m into the final position and achieved an
tensile bar system. This system provides
accuracy, both longitudinally and laterally,
a factor of safety in excess of 2.5.
of 2mm. The actual launching works took
The hydraulic jacks were controlled by an
seven hours, then the day crew returned
Isoflow pump and console, which enables
and completed decommissioning and
equal hydraulic flow and therefore equal
packing up the system. ●
Owner – VicTrack Access (V Line, Metro
and ARTC)
Main contractor – Thiess Balfour Beatty
Joint Venture
Designer – Parsons Brinckerhoff & SKM
(lead designers), Structural Systems
(specialist launching system)
Technology – Sliding
jack extension regardless of the individual
load in each of the bars.
1
ZURICH MAIN RAILWAY STATION, SWITZERLAND
Tunneling under southern wing
INNOVATIVE
TUNNEL CONSTRUCTION
With the Cross City Link project, a new railway line is currently under
construction in Zurich to connect the western part of the city with the main
station and Oerlikon station to the north. A significant part of the project
is the 4.8 km long Weinberg Tunnel – which runs into a newly built station
directly underneath the historical main station. Fabian Persch of local
BBR Network Member, Stahlton AG, describes his company’s innovative
approach to meeting the post-tensioning challenges of this major project.
1 Trolley with stressing jack.
2 Reinforcement and formwork of the
end beam.
3 Installation of monostrands with
deviation device.
TEAM & TECHNOLOGY
Client – Swiss Federal Railways (SBB)
Main contractor – ARGE Tunnel Weinberg
Oerlikon
Designer – Pöyry Schweiz AG
Technology – CONA electrically isolated
BBR Network Member – Stahlton AG
(Switzerland)
For a length of 110m, the new Weinberg
on diaphragm walls that provide lateral
Tunnel runs below the 150-year old heritage-
support as the basement is excavated.
protected southern wing of the station –
Due to the lack of access above ground,
thus, the tunnel had to be constructed
the slab and the diaphragm walls had to
without causing any structural damage to
be constructed using a conventionally
the building. Construction in close proximity
driven system of longitudinal and
to the southern wing, as well as the
transverse tunnels.
logistical difficulties involved with tunneling
A total of 29 support beams, which were
beneath an intensively used railway hub,
cast inside the transverse tunnels, form a
has required innovative solutions.
slab supported by the diaphragm walls.
Protected by this structure the actual
Construction method
tunnel works could be carried out. Once
The construction method chosen for the
completed the longitudinal tunnels will
undercrossing was a variation of the top-
function as access passages, from which
down solution. Top-down construction
the post-tensioning of the support beams
consists of a basement roof slab supported
can be checked and replaced if necessary.
Construction sequence
PT challenges
The size of the two 110m long longitudinal
For the design of the slab post-tensioning,
tunnels was designed to enable the
a multitude of boundary conditions had to
construction of the diaphragm walls and
be considered. Swiss Federal Railways’
the driving of the transverse tunnels. The
guidelines require all tendons to be
size of the transverse tunnels was given
electrically insulated. Also, potential
by the driving requirements and the static
replacement of tendons at a later stage
analysis for the support beams that had to
had to be ensured. The main challenge,
be installed. The driving of the transverse
however, was the extremely limited working
tunnels and the concreting of the beams
space in the tunnels. After concreting of the
was carried out using a step-back
end beam, the clear distance to the tunnel
procedure – that is, starting with the
walls was very narrow with a maximum
primary tunnels and followed by secondary
width of 1.50m. A strand overlength that is
tunnels between them. On average, every
normally required for tensioning tendons
eight working days a support beam could be
or destressing them for later replacement,
filled with up to 380m3 of self-compacting
was not available. Neither could
concrete. Subsequently, the end girders
conventional lifting equipment for the
which transfer the loads to the diaphragm
stressing jack be used in the narrow tunnel.
walls were concreted. The end girders
also contained the anchorages of the
Unique PT system design
post-tensioning tendons.
The post-tensioning system that was
eventually designed can certainly be
2
considered unique. The tendons consisted
of sheathed monostrands, which were
pushed into cast in-situ plastic pipes in the
transverse beams. To make sure that they
withstand the concrete pressure, the pipes
were filled with water during concreting.
The strand coils had to be placed outside
the tunnel – and the monostrands had to be
pushed through using a long guide tube and
special deviation device. In total, 3,600m of
post-tensioning tendons – amounting to
80t of prestressing steel – were installed in
the supporting load transfer slab.
Tendon stressing was carried out with a
bell-shaped grip, which was screwed onto
the threaded anchor-heads and pulled by a
specially manufactured stressing jack.
Shims were placed between the stressed
anchor heads and the bearing plates to
maintain the elongation. Destressing of the
cables at a later stage is achieved by simply
removing the shims. Thus a strand
overlength was not needed for stressing or
for replacement.
For placing the jack which weighed around
1,000kg, we designed and manufactured a
suitable lifting trolley that could be moved
along the end girder. After tendon stressing,
the anchorages were sealed and the tendons
were electrically insulated from the structure.
After completion of the post-tensioning, the
bracing loads from the slab were transferred
actively to both diaphragm walls – then the
tunnel excavation works under the
completed transfer slab could begin. ●
3
1
CONTAINER TERMINAL, PORT OF RIJEKA, CROATIA
Post-tensioned beams
CONTAINING
STRENGTH
FOR ADRIATIC
Since it first opened some 25
years ago, container traffic through
Rijeka’s Brajdica Container
Terminal has constantly increased.
Despite the economic recession,
this trend has continued and
increasing its capacity was vital to
ensure future success of the facility.
Kresimir Bogadi of Croatia-based
BBR Adria takes up the story.
The Brajdica Container Terminal sits on
Croatia’s Northern Adriatic Sea coastline,
on the southern side of the Rjecina river
delta, south of the city of Rijeka. The project
to increase capacity at Brajdica is part of
the wider Rijeka Gateway Program to
improve life and facilities for citizens, as
well as to attract private investment into
the area – and maximize the use of the port
in a competitive market place.
The Terminal’s busiest year, in 2008, saw
more than 170,000 TEU (20 foot equivalent
units) containers being transshipped.
1 The new quay for the Adriatic Gate Container
Terminal near Rijeka takes shape at the busy
container port.
2 Work in progress to connect the coastal
ring beam and anchor wall behind using
BBR VT CONA CMI / CME tendons.
The capacity of the existing container
terminal is estimated to be 250,000 TEUs
per year, mainly due to the limited container
storage space.
2
Phase II outline
Construction of Phase II of the Terminal
includes a 328m extension of the coast
INDUSTRIAL HARBOR, HORSØY, NORWAY
Two stage installation of ground anchored crane base
and construction of a 50,000m2 storage
area – effectively doubling container
services arriving or departing. Improved
LIFTING POWER
rail loading facilities for a larger number
In Kleppestø, near Bergen in western Norway, BBR Network Member
storage capacity. There will also be a
new checkpoint on the D404 road to
enable rapid truck transit and unify all
of containers is also part of the planned
upgrading program.
Spennteknikk has carried out a two-staged ground anchoring operation
As a part of the second phase of
for foundations forming a harbor crane base. Stig Sjolbør describes his
construction of the Brajdica Container
company’s work.
Terminal, 14.5m deep berths have been
built to enable safe mooring of larger
Stage 1, the foundation works, started in
Making the connection
container ships. BBR Adria is installing
spring 2010 with plans already in place to
We returned to site, some months later,
25 BBR VT CONA CMI / CME tendons in
install a crane on the harbor in the future.
to carry out the second stage of the
the quay wall – to connect the coastal
Therefore, when constructing the harbor,
project. We installed a further 18 BBR VT
ring beam and anchor wall behind. The
the foundations were built with this in
CONA CMG ground tendons of lengths
tendons are formed in two parts.
mind – a ground anchor with a K-coupler
between 4.5-6.6m and connected the
was installed to allow later connection of
strands to the K-couplers already
the crane to the foundation.
installed during Stage 1, then the concrete
Two part PT tendons
The first part is in the coastal ring beams
wall was poured.
and is 3m long, consisting of a CONA CMI
Post-tensioning works
The steel crane connection was fixed in
1206 passive anchorage and CONA CMI
We used 16 x 150mm2 BBR VT CONA CMG
place after the concrete had hardened
1206 coupling anchorage. This part of the
ground tendons with a length of between
and then we stressed and grouted the
tendon was grouted with cement grout
28-33m. The post-tensioning strands
tendons. When the crane itself had been
after stressing.
were 15.7mm in diameter with an Ultimate
mounted, it was successfully tested with
The second part of the tendon is a
Breaking Strength of 1860N/mm2 –
a load of 400t. ●
replaceable BBR VT CONA CME tendon
greased and plastic coated on the free
connected to the first part with a CONA
length.
CMI 1206 coupler. Construction of these
The main contractor performed the
removable tendons was performed such
casting of the foundations and our client
that the tensioning element has multiple
performed the drilling works. We installed
corrosion protection on its whole length.
and grouted the permanent anchors and
The CONA CME tendons are each made
then we stressed the K-coupler anchors.
up of 12 galvanized strands individually
Then, we mounted a protective grease-
greased and sheathed and further
filled cover over the anchorage, for
protected in a 110mm diameter HDPE pipe.
connection when the crane was ready to
The new quay, at the now renamed
be installed.
TEAM & TECHNOLOGY
Owner – Horsøy Industrihavn AS
Client – Kynningsrud Fundamentering AS
(Stage 1), Framo Engineering AS (Stage 2)
Main contractor – Veidekke AS
Designer – Norconsult AS
Technology – BBR VT CONA CMG ground
BBR Network Member – KB Spennteknikk
AS (Norway)
Adriatic Gate Container Terminal (AGCT),
was officially opened by Sinisa Hajdas
Doncic, the Croatian Minister of Maritime
Affairs, Transport and Infrastructure,
during 2013. AGCT is now poised to
support the Port of Rijeka in becoming
one of the most competitive container
ports on the Adriatic. ●
TEAM & TECHNOLOGY
Client – Port of Rijeka
Main contractor – GP Krk
Designer – Rijeka projekt
BBR VT CONA CME external
(Croatia)
1
2
EARTHQUAKE RESISTANT BUILDINGS, CANTERBURY, NEW ZEALAND
Application of PRESSS technology
DIVERSITY IN
PRESSS
TECHNOLOGY
2 Trimble Navigation offices,
Christchurch
While Trimble Navigation’s Christchurch
office survived the 2010 and 2011
earthquakes, it was not destined to last for
long – in 2011, the entire building was
destroyed by fire.
Replacing it will be the first building in New
Zealand constructed with post-tensioned
LVL frames and post-tensioned LVL walls.
Standing two storeys high, it will also include
clever devices that reduce earthquake
PRESSS (PRecast Seismic
Suited to steel, concrete and LVL
damage by dissipating the energy and
Structural System) technology
(laminated veneer lumber) structures,
controlling movement in the structure itself,
PRESSS technology delivers protection
as well as beam column joints with forced
against serious earthquakes while
rocking points which control joint movement
especially in Canterbury, as
minimizing seismic damage and the
and damage. The energy dissipaters can be
part of the post-earthquake
associated costs of smaller tremors.
easily replaced after an earthquake,
is taking New Zealand by storm,
providing economical repair alternatives.
rebuild program says BBR
Contech Southern Regional
Manager, Peter Higgins.
1
Police station, Rotorua
building’s nine LVL shear walls and 19
will soon be based in a brand new police
horizontal LVL beams. That means:
station – and not a moment too soon
• installing 54 x 50mm diameter PT bar
according to those working in the existing
tendons vertically through the walls and
premises.
connecting them to screwpiles that
The two-storey station is being constructed
using PRESSS technology, with tensioning
TEAM & TECHNOLOGY
1 Client – New Zealand Police
Main contractor – Canam Construction
Engineer – Spiire
Technology – BBR VT CONA CME
external
(New Zealand)
2 Client – Birmingham Drive Properties
Ltd
Main contractor – City Care Limited
Engineer – Opus International
Consultants
Technology – BBR VT CONA CME
external, PT bar
(New Zealand)
BBR Contech’s role is to post-tension the
Police officers serving in the Rotorua area
terminate in the gravel layer
• installing six multi-strand, 15.2mm
cables installed in the concrete shear
diameter strand tendons in each beam.
walls, beams and columns to allow it to
The tendons are greased and sheathed
move in an earthquake without sustaining
to protect against corrosion and the ends
serious damage.
are wrapped in corrosion protection tape
For this project, the BBR Contech team is
and capped to provide an additional
installing 62 BBR VT CONA CME 12-strand,
barrier against the elements.
greased and sheathed tendons into the
In another innovation, the building’s
precast walls.
strength will be constantly monitored – and
The new station is due to open in March
tendons easily removed and replaced if
2014, offering an environment eminently
necessary. The project, and its impressive
suited to modern-day policing while
commitment to earthquake resistance, is
reflecting the unique features of Rotorua,
already earning accolades – it won a ‘highly
particularly the prominence of Maori art
commended’ award in the 2012 Timber
and culture.
Design Awards. ●
DENISON ROAD GRADE SEPARATION, TORONTO, CANADA
Ground anchoring
ANCHORING
IN TORONTO
1
2
3
4
5
6
Work is underway in the Denison
1
Road area of Toronto on a major
grade separation project to
improve railway services and
A tieback drilling machine bored holes,
minimum grout strength of 28MPa
38m long ground anchors which would
had been achieved, the tendons were
later be grouted and tensioned against
stressed, proof tested and locked-in.
the sheet piled wall.
A typical stressing activity is shown
accommodate a new airport rail
link. Tim Pahapill of BBR Canada
explains, through the photographs
5 After installing the anchors and a
under artesian conditions, for the up to
here with the team stressing the ground
2 For ease of fabrication, transportation
anchors against the external bracket
and to save time on site, tendons were
mounted on the sheet piled retaining
delivered in cut-to-length coils and an
wall beneath the new railway bridge.
below, how their work involves the
uncoiling turntable was used to unwind
installation of up to four layers of
them during installation.
6 The first two rows of ground anchors
are fully installed and stressed to their
ground anchors along a sheet-piled
3 Once installed and the bored hole fully
prescribed lock-in loads. The first row
grouted, the strands were individually
is finally capped and the second row is
below the railway line. As can be
secured in the anchor heads by placing
being prepared for capping. ●
seen, the ground conditions are
wedges into the anchor head wedge
extremely challenging.
holes.
retaining wall which forms a cutting
4 After installation, the ground anchors
were filled with a special grout mixture
as a corrosion inhibitor and to create
the bonded length, while the free
stressing lengths remained greased
and sheathed for protection.
TEAM & TECHNOLOGY
Owner – Metrolinx
Main contractor – Dufferin Construction
Company
Shoring & drilling contractor – Deep
Foundations Contractors Inc.
Technology – BBR CONA ground
BBR Network Member – Canadian bbr Inc.
(Canada)
PORTFOLIO MRR
EASTERN INTERCEPTOR SEWER, AUCKLAND, NEW ZEALAND
Specialist refurbishment & treatment of damaged sewer
GOING
UNDERGROUND
The term ‘Eastern Interceptor’ may sound like a fighter jet left over from the
days of the Cold War, but for the BBR Contech team the expression has a
distinctly different meaning explains their Project Manager, Oliver Smith.
1
Completed in 1962, the Eastern Interceptor
Watercare – the company providing water
is a large-diameter, reinforced-concrete
and wastewater services to the Auckland
wastewater pipe that follows a 19km path
region – maintains a rigorous monitoring,
from Auckland’s Okahu Bay to the
maintenance and, where necessary, repair
Mangere Wastewater Treatment Plant.
program. BBR Contech was most recently
It is a vital part of the city’s wastewater
involved in 2005, when we repaired several
management system, carrying about
sections in what was thought to be the first
two-thirds of its wastewater and acting
large-scale remedial concrete works to be
as the main collection point for many
carried out in a fully live, man-entry sewer
large and small sewers. For this reason,
in New Zealand.
PORTFOLIO MRR
“This has required us
to take a scrupulous
approach to planning
and implementing
the project, and to
keeping the affected
community well-informed
along the way.”
2
Meticulous detail
Work like this is never pleasant for the
BBR Contech team, with a hazardous
working environment in which everyone
is required to follow stringent health and
safety policies. These include wearing dry
suits equipped with adequate supplies of
fresh air – and maintaining a strict limit
on the time spent in the underground pipe
environment. In Mount Wellington, the
team also has to have a constant focus on
minimizing noise and other disruptions to
the residents nearby.
Spread over two stages and due for
completion in early 2015, the project
involves:
3
• preparing the surface using robotic
high-pressure water blasting, which is
very effective in removing the affected
1 Auckland’s Eastern Interceptor Sewer is a
19km long reinforced concrete pipe which
required vital man-entry maintenance works.
2 Wearing of dry suits equipped with fresh air
supplies and adhering to strict underground
time limits form part of the health and
safety regime on BBR Contech’s sewer
maintenance projects.
3 Preparation of the sewer pipe surface is
carried out using high pressure blasting, then
a specialist spray is applied to the walls to
protect against biogenic sulphide corrosion.
TEAM & TECHNOLOGY
Client – Watercare Services
Engineer – AECOM
Technology – MRR range
(New Zealand)
Latest contract
We have recently been called upon again,
concrete without disturbing raw sewage
• applying 350t of specialized coating –
this time to remove and replace damaged
a technologically sophisticated calcium
concrete in two other parts of this critical
aluminate product that is sprayed on to
element of Auckland’s infrastructure –
provide highly effective, high-strength,
one a 205m-long section at the wastewater
corrosion-resistant protection against
plant itself, and the other a 440m-long
biogenic sulphide corrosion.
section in Mount Wellington. The latter is
While those working on the project will no
posing some particularly complex
doubt be relieved to see it completed, they
challenges for the team, as it is located in
can be very proud of their role in helping to
a heavily populated residential area which
ensure that Auckland’s wastewater system
includes a primary school. This has
continues to perform well into the future.
required us to take a scrupulous approach
For our part, the project has reflected the
to planning and implementing the project,
very best of expertise, experience and
and to keeping the affected community
collaboration – qualities that we at BBR
well-informed along the way.
Contech promote and value highly. ●
PORTFOLIO MRR
1
2
BULACAN LINE 2 CEMENT SILO 9, NORZAGARAY, BULACAN PROVINCE, PHILIPPINES
Design, retrofitting & post-tensioned construction
STRENGTHENING FOR
EUROCODE COMPLIANCE
BBR Network Member, BBR Philippines Corporation has provided
“A retrofitting system
post-tensioning services at a plant belonging to one of the world’s largest
was needed that would
cement producers – the Swiss-based Holcim Group. Rey Singh outlines
not require a shutdown
the story behind the project.
of the silo while the works
The existing cement plant in Norzagaray,
Technical aspects
were being executed.”
Bulacan Province was acquired by Holcim
Time was now of the essence and pressure
in 2004 to increase their local production
was on to increase much-needed storage
capacity. As they require their structures to
capacity without disrupting the plant’s
be compliant with both local and European
commercial operations. A retrofitting
construction codes, they tasked a European
system was needed that would not require
engineering consultancy firm to undertake
a shutdown of the silo while the works were
the necessary design reviews.
being executed.
Their study for Cement Silo 9, which was
Silo 9 is a 41m high, 10,000MT cement
built in 1995, showed that it needed to be
storage silo with an inside diameter of
structurally upgraded to conform with the
20m and wall thickness of 650mm. It also
local codes, ACI provisions and European
has an annex wall with a 10.524m curvature
code requirements for silos considering the
length jutting out on one side as this was
dynamic forces acting during extraction in
intended for the future construction of
concrete silos with inverted cones. They
Cement Silo 10 – Cement Silo 9’s twin silo.
1 External post-tensioning is being applied to
the external wall of the cement silo for
strengthening in line with Eurocode
requirements.
2 Work at the cement plant was able to continue
while work was in progress – a benefit of
adopting an external post-tensioning solution.
TEAM & TECHNOLOGY
Owner – Holcim Philippines, Inc.
Main contractor – BBR Philippines
Corporation
Technology – BBR CONA external
BBR Network Member – BBR Philippines
Corporation (Philippines)
recommended that Cement Silo 9 be
limited to a 40% storage capacity until it
had been strengthened to conform to
Eurocode standards.
PORTFOLIO MRR
MOUNT VICTORIA TUNNEL, WELLINGTON, NEW ZEALAND
Strengthening with ground anchors
ORCHESTRATING
TUNNEL ACTIVITIES
The journey between the City of Wellington and its airport, takes
motorists through the Mt Victoria tunnel – where many take part in the
symphony of tooting horns that’s long been customary practice as the
vehicles pass through. With more than 620m to cover, there’s plenty of
time to raise a tune! Recently, motorists have acquired a new audience –
External post-tensioning works
We proposed to upgrade the structural
the team from BBR Contech which has been carrying out strengthening
work on concrete walls at the tunnel’s entrance and exit portals.
capacity of the existing Cement Silo 9
through external post-tensioning tendons.
Opened in 1931, the tunnel was the first
Therefore, New Zealand Transport Agency
The use of external post-tensioning tendons
road tunnel in New Zealand to be
have awarded BBR Contech the contract
has the flexibility to avoid obstructions,
mechanically ventilated. The technology
for strengthening the tunnel’s concrete
like the existing structures and services
remains an important feature today, as
walls at the entry and exit portals.
attached to Silo 9, and allows the contractor
the tunnel is now a thoroughfare for about
The project will anchor the walls in place
to work on the outside surface of the silo
45,000 vehicles a day, as well as hundreds
to reduce the risk of damage or collapse
wall without interfering with the cement
of pedestrians and cyclists.
in an earthquake. Given the weak ground
plant’s operations.
The tunnel is a vital piece of infrastructure
conditions at the site, this is a complex
The post-tensioning tendons are BBR
on State Highway 1 and keeping it in top
task involving building a concrete beam to
CONA external tendons, each with four
condition is of prime importance.
link the anchors through the walls, adding
0.5” unbonded strands. The grease and
steel as extra reinforcement, installing the
polyethylene sheathing of the unbonded
anchors and cementing them in place with
strands serve as corrosion barriers as they
high-pressure grouting to ensure a firm,
are exposed to the elements in the sectors
long-lasting bond.
between the three reinforced concrete
The work has been arranged to have
buttresses built to house the tendon
minimal impact on those using the tunnel
anchorages. A total of 89 BBR CONA
and, thanks to some careful screening, the
external tendons were looped around the
construction workers are no distraction
cement silo.
for drivers. Noise and traffic management
Besides overcoming obstructions, limited
plans are also helping to reduce the
working spaces and access problems due to
effects for those in the neighboring
the height of the silo, another major obstacle
community, while a communication
was the removal and demolition of the
strategy ensures that those directly
annex wall as this obstructed the installation
affected are kept up-to-date on progress. ●
of the post-tensioning tendons in its sector.
1
Diamond saw cutting machines, set up on
1 The tunnel walls are being strengthened at
the entry and exit portals.
2 The BBR team is screened from the road
beneath while they grout the new anchors
installed for the tunnel strengthening program.
heavy duty modular ring lock scaffolding,
were used to cut the annex wall segment-bysegment. The segments were individually
brought to ground level by a mobile,
telescopic crane and hauled away from the
construction site.
Cement Silo 9 has now been loaded to
100% filling capacity – and its owners can
TEAM & TECHNOLOGY
be confident that it meets all required
Client – New Zealand Transport Agency
Engineer – Opus International Consultants
Technology – BBR CONA ground
(New Zealand)
construction codes. Mabuhay!* ●
* For our non-Filipino readers, this is a frequently used local
greeting meaning 'live' – as in 'live your life' or 'live long'.
2
PORTFOLIO MRR
1
2
NORTH RJECINA MOTORWAY BRIDGE, CROATIA
Rehabilitation with external post-tensioning
FIRST REHAB
IN 30 YEARS
The old northern Rjecina bridge was built between 1980 and 1984 and
opened to traffic in 1988 when the whole section of motorway around
the city of Rijeka had been completed. Since it opened, no rehabilitation
work had been carried out on the bridge.
1 External post-tensioning tendons were
replaced as part of the bridge abutment
rehabilitation project.
2 View of one of the carriageways as work had
almost been completed – this was the first
rehabilitation project carried out since the
bridge opened in 1988.
TEAM & TECHNOLOGY
Client – HAC, Zagreb
Main contractor – Viadukt d.d., Zagreb
Designer – Institit IGH d.d., Zagreb
Technology – BBRV wire
(Croatia)
The bridge is positioned around 100m above
PT tendon replacement
the river valley. The bridge main span is
As a part of the abutment rehabilitation,
98.4m with lateral 45m spans supported on
the external tendons which take over lifting
sloping piers and an additional independent
force were replaced. In accordance with the
17.5m span on the west side which was
design specifications, 32 x 7mm diameter
required for tricky geological conditions.
BBRV Wire post-tensioning tendons were
The foundation axis span is 131.65m.
used. The upper part of the tendons were
anchored with movable anchor heads, while
Rehabilitation work
the lower parts were anchored with passive
Rehabilitation work consisted of asphalt
non-movable anchor heads.
and superstructure hydro-isolation
Each strand was fixed into the anchor head
replacement, abutment rehabilitation,
using the cold-formed button heading
abutment expansion joint replacement
process which ensures maximum efficiency.
and rehabilitation of other installations.
There were four 4.5m long tendons on each
abutment. After replacing the wires and
anchor heads, each tendon was stressed to
a force of 200kN.
Corrosion protection of the tendons was
completed using new grease-filled HDPE
pipes and protection caps. ●
TECHNOLOGY
64 RESEARCH & DEVELOPMENT
improving all round performance
– stay cable dampers to counter
vibration, plus cost-effective
grouting accessories
68 TECHNICAL UPDATE
securing of AASHTO approval
and current status of the
BBR VT CONA CMX range
70 TECHNIQUES
Fabian Persch of Stahlton, the
BBR Network Member for
Switzerland, reveals the benefits
of and method for prefabricating
PT tendons
72 INSIGHT
technology and expertise from
the BBR Network can breathe
new life into weakened or
damaged infrastructure and
buildings – some of the techniques
are showcased here
TECHNOLOGY
RESEARCH & DEVELOPMENT
Superior countermeasure for stay cable vibration
SOLUTIONS FOR
COUNTERING
CABLE VIBRATIONS
Cable-stayed bridges have been built in greatly increasing
Even newly constructed cable-stayed
numbers since 1950. Despite their wide use, there are
bridges have experienced quite severe
still several areas of great concern, especially the effects
vibrations – such as, for example, the
Fred Hartman Bridge in Houston, Texas
and elimination of cable vibration phenomena. Within the
which has a main span of 381m and 192
BBR technology range, we offer a superior supplemental
stay cables. Excessive cable vibrations
passive damping device – the BBR Square Damper – to
have also been observed on numerous
combat cable vibrations.
other bridge structures.
Several cable vibration mechanisms have
been identified – such as vortex shedding,
cable galloping, parametric excitation
(deck / pylon and cable interaction) and
wind-rain induced vibrations – which
create concern generally.
1
TECHNOLOGY
Cable galloping
were of the order of 0.55m when subjected
Galloping was firstly detected in power
to the effects of a 14 m/s wind.
lines which – under certain weather
Today, it is also known that the action of
conditions – were observed to be vibrating
the rain leads to the formation of two water
and exhibiting high amplitudes at
rivulets, one on the upper cable side
relatively low frequencies. Curiously, this
(unstable rivulet) and another on the down
phenomenon has never been reported in
cable side (stable rivulet). Although the
countries with a warm climate, but it is
presence of the rivulets slightly changes
very common during the winter months
the outer cable shape, some experiments
in northern states of USA and Canada.
performed by Yamaguchi in the 1990s
Oscillations are transversal to the wind
showed that the vibration was very unlikely
direction, occurring at frequencies close
to be caused by a ‘galloping-like’
to some natural frequency and generally –
mechanism – but rather the oscillatory
for all wind speeds – above a critical value.
movement of the top rivulet, caused by the
In general, to ensure stability of the stay
combination of gravity and aerodynamic
cable under galloping-like mechanisms, the
forces. Past experience and intensive
following expression must remain negative:
experiments in the field demonstrated
that rain-wind instability occurs under the
following conditions:
• wind flows in the same direction as the
cables decline from the pylon to the deck
In which m, fk and D are, respectively, the
linear mass, natural frequency and outer
diameter of the cable. On the other side,
• combination of light rain with relatively
• outer surface of the stay pipe is smooth
U corresponds to wind speed and the term
and not equipped with any
in brackets to the Den Hartog Coefficient.
countermeasure, such as helical rib or
A detailed analysis of the above expression
Analysis from earlier stay cable bridges
subjected to galloping when the Den Hartog
shows that rain-wind induced vibration
Coefficient becomes negative, which may
may be overcome if the Scruton number is
happen under the following conditions:
high enough:
• outer shape of the stay pipe is not circular
• Sc > 10, if stay pipe has a smooth outer
which noticeably modifies outer shape to
non-circular
Upper rivulet (unstable)
dimples.
will show that stay cables will only be
• accumulation of ice on the stay pipe
Rain
moderate wind speeds of around 8-15 m/s
Lower rivulet (stable)
surface
• Sc > 5, if stay pipe is equipped with a
helical rib or similar countermeasure. ➤
Illustration showing a cross section of an HDPE stay pipe
• wind flows on a plane non-orthogonal to
the stay cable’s axis.
Wind-rain induced vibrations
The phenomenon of rain-wind induced
HDPE stay pipe
vibration is brought about by the
simultaneous action of a low / moderate
wind speed, together with the action of rain.
Upper rivulet (after)
Upper rivulet (before))
Nowadays, it is considered that rain-wind
induced oscillations cause about 95% of
the reported vibration problems in cablestayed bridges. In spite of this, it was not
1)
2)
until the construction of the Meiko-Nishi
Bridge in the 1980s that this phenomenon
in cable-stayed bridges was reported for
the first time. During construction, it was
observed that the cables of the bridge –
initially stable with respect to the action of
the wind – started to become unstable in
Illustration showing the movement
of rivulet due to gravity (1)
Illustration showing the movement
of rivulet due to wind flow (2)
rainy conditions. Oscillations observed
TECHNOLOGY
Dampers for Rio Corgo
Due to its simple design, high efficiency,
Completed in 2013 by BBR Network
easy adjustability and low maintenance
Member BBR PTE, Portugal’s Rio Corgo
requirements, the BBR Square Damper
Viaduct features 88 HiAM CONA stay
is superior compared to other damping
cables – ranging in size from 42 to 69
products available on the international
strands, with the longest cable measuring
market. The device can be fine-tuned
159m. Following extensive cable vibration
and adjusted during its entire service life
analysis, performed by the BBR HQ
to best suit a particular cable configuration
Technology and R&D team based in
and specific susceptibilities to particular
Switzerland, it was determined that 16
vibrations. All components of the damper
of the 88 stay cables would require
can be inspected individually and are
additional supplemental damping to
replaceable if required – for example, if
eliminate cable vibrations.
there has been external damage or
The BBR Square Damper is a superior
vandalism. ●
supplemental passive damping device
which is based on friction. The device
can be used as an internal damper, where
it is installed inside the steel guide pipe
or alternatively as an external damper,
attached to the cable free length using a
damper housing and external brace.
The main advantages of the BBR Square
Damper are:
• the damper is not activated at
low and non-critical cable vibration
amplitudes, avoiding constant
working of the damper and
minimizing maintenance
requirements
• the damping efficiency is
independent of the acceleration
and mode of cable vibration
• the damper has been proven, by
testing, to achieve the Maximum
Passive Supplemental Damping
considered for a ‘perfect damper’
and thus the safety factors relating
to Required Supplemental
Damping can be reduced
• free longitudinal movement of the
stay cable at the damper location is
provided, allowing for temperature
elongation and force variations of
the stay cable without constraints
• the damping characteristics can
be adjusted at any time by changing
the ‘clamping’ force
• high endurance and constant
performance
• easy inspection and low maintenance.
2
1 For Portugal’s Rio Corgo Bridge – completed
by Spanish BBR Network Member, BBR PTE
– the BBR HQ Technology and R&D team
performed extensive cable vibration analysis
and determined that 16 of the 88 stay cables
would require damping.
2 The BBR Square Damper is a superior
supplemental passive damping device which
is based on friction and can be installed as
an internal or external damper.
TECHNOLOGY
RESEARCH & DEVELOPMENT
New generation of grouting accessories
GREEN AND
COST-EFFECTIVE
Grouting plays a key role in the
In the industry as a whole, there have
This has enabled us to ensure that material
corrosion protection of post-
been concerns associated with the grouting
usage was fully optimized – so that we use
process for post-tensioning tendons and
just what is needed and no more.
these are associated with potential impacts
The range of accessories also includes
BBR Network has developed
on both the construction program and
a newer series of BBR grouting caps,
excellent techniques for
environment. Therefore, we have developed
made of organic polymer. They are able
completing this important task.
a new range of grouting accessories
to withstand grouting pressures of up
specifically for the BBR VT CONA CMI and
to 15 bars and are fully compatible with
CONA CMM post-tensioning systems which
anchorages and couplers. The new caps
accessories this process has
improve efficiency and sustainability.
showed significant cost reduction and
become even more cost-effective
Among the tools our team used during the
an extraordinary reduction of the CO2
and environmentally friendly.
development process of our new range was
emissions to the atmosphere. ●
tensioning tendons and the
Now, with our new range of grouting
non-linear finite element analysis.
1
1 The new grouting caps reduce costs
and environmental impact.
2 Finite element analysis of the new
grouting caps.
2
TECHNOLOGY
TECHNICAL UPDATE
New approvals & renewals
AASHTO
APPROVAL
FOR CONA CMI
1
While ETAG 013 has become
BBR HQ has recently carried out additional
Finite element modeling
state of the art in Europe and
initial type testing on the CONA CMI BT
While experimental testing gives global
system according to AASHTO LRFD
information about the performance of the
Bridge Construction Specifications,
CONA CMI BT anchorage system – for
2nd Edition, 2004.
example, wedge slippage, deflection, etc –
other regions worldwide, some
regions – such as the Middle
East – specify post-tensioning
projects according to AASHTO.
no internal information, such as stress /
System testing
strain in the anchorage core at service and
Among other items, the system testing
ultimate state, can be obtained. In addition,
included:
experimental tests are recognized as being
• static load tests including the deviation
time-consuming and expensive. However,
of the strands to represent the transition
by using the latest finite element modeling
zone at the exits of the anchorage and
technology, our numerical analyses have
at the coupler unit on PT tendons with
complemented laboratory testing and
up to 6106 strands
confirmed geometrical, material and
• load transfer tests for highly aggressive
surface anchorage properties.
environments and concrete strength
The finite element model takes into account
range from 19/23MPa to 35/43MPa on
all the mechanical behavior complexities
PT anchorages with up to 6106 strands.
which occur on CONA CMI anchorages
The recent AASHTO approval tests
when subjected to heavy prestressing
confirmed the benefits of the
loads, such as the wedge-tendon gripping
CONA CMI BT system, with static load
interaction, the friction at the wedge-anchor
efficiency greater than 96% AUTS and
head interfaces, as well as at the anchor
reduced crack width at the local zone for
head-anchor plate interface, local plasticity
its application in those special aggressive
and large displacements at the wedge-
environments described in AASHTO LRFD
anchor head interfaces.
Bridge Construction Specifications.
Anchor head deflection and radial
deformation data collected from the
testing formed the basis for comparison
with the numerical results. The agreement
observed, between the experimental and
numerical results, clearly showed the
benefits of finite element modeling for
assessing both the global and local
behavior of the anchorage system.
1 Finite element modeling (FEM) also
proved to be beneficial for assessing
both the global and local behavior of the
CONA CMI BT anchorage system.
2 Laboratory testing of the CONA CMI BT
system confirmed the benefits of the
CONA CMI BT system for application in
special aggressive environments as
described in AASHTO LRFD Bridge
Construction Specifications.
The CONA CMI BT system has now been
applied to the two 160m long flyovers at
the Barka Interchange, part of the new
Batinah Expressway project near Muscat,
Oman. More information about the
project is on page 32. ●
2
TECHNOLOGY
BBR VT Plastic Duct
The European Technical Approval for the
BBR VT CONA CMI internal bonded posttensioning system with 04 to 31 Strands –
ETA-06/0147, has been recently renewed
up to March 2018. This approval now
includes the BBR VT Plastic Duct which
has the following key features:
• BBR VT Plastic Ducts are circular with
inner diameters from 50mm to 130mm
and they are made of polypropylene with
toroidal corrugations
TECHNICAL UPDATE
• BBR VT Plastic Ducts were tested in
accordance to fib bulletin 7, for a working
New approvals & renewals
temperature range of –20°C to +50°C
• Enhanced corrosion protection against
aggressive chloride environment
STATUS OF
CONA CMX
APPROVALS
• Lower and more reliable friction
coefficient, beneficial for longer tendons
and circular tank construction
• Reduced risk of fretting fatigue of tendons
Recent renewal of ETAs
The following European Technical Approvals
have been renewed for the next five years:
• BBR VT CONA CMI SP – Internal bonded
post-tensioning system with 01 to 61
strands – European Technical Approval
ETA-09/0287, renewed up to June 2018
• BBR VT CONA CMI BT – Internal bonded
post-tensioning system with 02 to 61
strands – European Technical Approval
Our BBR VT CONA CMX range of completely new post-tensioning
technology was launched in 2006 and, since then, European Technical
ETA-09/0286, renewed up to June 2018
• BBR VT CONA CME – External posttensioning system with 04 to 31 strands –
Approvals (ETAs) have been progressively sought, awarded and renewed
European Technical Approval ETA-07/0168,
for different systems within the CONA CMX range. This is a significant
renewed up to December 2017.
investment – in terms of both time and costs – however, it has ensured
that the BBR Network has the latest CE-marked, high quality technology
to offer its customers.
National CONA CMX approval updates
In Australia, CONA CMI BT has been
approved for sizes up to 6106 by the
Roads and Maritime Service (RMS) and
The CONA CMX range was developed
BBR VT CONA CMM Single
has been used by local BBR Network
in response to market needs and offers
The new BBR VT CONA CMM Single
Member, Structural Systems on the
considerable budget, program and
European Technical Approval ETA-12/0282
Hunter Expressway project (see page 21).
environmental benefits – such as less
has been issued and is valid until June 2018.
CONA CMI has also been approved in
space needed in the anchorage zone,
The key features and benefits of the new
Switzerland, with Stahlton as the local
stressing at lower concrete strengths
internal system with single strand are:
PT Specialist. This approval is based on
and reduced requirement for
• Applicable for bonded applications
the CONA CMI European Technical
reinforcement in the anchorage zone.
with corrugated steel or plastic duct
Approval ETA-06/0147 and includes the
Securing and maintaining ETAs for our
• Applicable for unbonded tendons with
full range of BBR VT Plastic Ducts (both
CONA CMX systems is important, as
grease / wax as filling material or with
round and flat) and specifications relating
they are the everyday technologies used
monostrands
to prefabricated tendons.
by BBR Network Members for delivering
the highest quality services to their
customers worldwide.
• Exchangeable and restressable for
unbonded tendons
• Full stressing at low minimum concrete
strength (20/24MPa).
Meanwhile, in Germany, the Deutsches
Institut für Bautechnik (DIBt) has extended
approval of our external band systems for
general use for another term. ●
A complete series of the latest approvals – along with CAD drawings and technical brochures –
is now available for download from our website – www.bbrnetwork.com/downloads/approvals.html.
TECHNOLOGY
1
TECHNIQUES
2
Prefabrication of post-tensioning tendons
REELING
WITH SUCCESS
While it is not a new idea, the
Our experience of prefabricating post-
off-site prefabrication of post-
tensioning tendons stretches back to the
tensioning tendons can offer great
early days of the shared BBR and Stahlton
history. Unlike strand tendons, wire cables
benefits for certain construction
need to be cut to an exact length, which
projects. With its history of being
can be best carried out in a workshop.
a wire tendon supplier, the BBR
So it has become customary for us to
Network Member for Switzerland,
fabricate our tendons off-site.
We have found that prefabrication offers
Stahlton AG developed the
a number of advantages for both the
infrastructure and capability
BBR PT Specialist and the client:
necessary to prefabricate tendons
• greater program / time flexibility for
many years ago. Today, they still
both fabrication and installation on site
• clean and efficient fabrication
prefabricate the bulk of tendons
• speedy installation on site
for use on their projects. Fabian
• smooth, problem-free strand-pushing
Persch, Product Manager PT, of
Stahlton outlines the background,
advantages and the process.
operation
• potentially smaller ducting diameter and
hence greater effective depth achievable
Generally, the prefabricated tendons are
coiled onto reels, shorter tendons might,
however, be delivered loose or on trusses.
While off-site tendon prefabrication is our
preferred option, this is not always possible.
A number of factors – such as length and
weight of tendons, duct diameter, as well
as the available space and clearance on
site – may dictate that on-site cable
fabrication is necessary.
TECHNOLOGY
3
5
1
Strand installation in the workshop
The fixed strand pushing arrangement allows for speedy
and efficient strand installation.
4
2 Coiling onto reel
Usually, tendons are coiled onto the reels with the help
of a fork-lift truck. The reels must be of an appropriate
diameter, to avoid cracking or kinking of the sheathing.
3 Transportation to site
The reels of tendons are loaded onto a truck, along with
the uncoiling frame, for delivery to the construction site.
4 Storage
Tendons must be stored in sheltered conditions prior
to installation to protect them from water ingress.
5 Uncoiling
Here, the tendon reel is being secured to the uncoiling
frame and being lifted by a crane.
6 Tendon placement
Placing of a tendon into position as it is being uncoiled.
The uncoiling frame, with its braking device, must be
operated by experienced staff only. The handling
requires certain procedures to avoid uncontrolled
6
overturning or uncoiling. ●
TECHNOLOGY
INSIGHT
MRR technology and techniques used by BBR Network Members
REVIVING
THE BUILT
ENVIRONMENT
It is well-recognized that BBR
technology promotes leaner new
construction, but what about
maintenance, retrofit and
restoration or renovation (MRR)
projects? With the three ‘Rs’ –
Reduce, Reuse, Recycle – playing an
ever greater role in a cost-conscious
and environmentally aware world,
specialist techniques and
technology used by BBR Network
Members are also delivering leading
edge green and economic solutions.
The need for the BBR Network’s range of
MRR techniques arises from a number
of factors. Often, it is a case of repairing
damage whether through prolonged or
heavier-than-planned usage or
insufficiencies in the original design of a
building – although constructed to the
highest standards of the day, several
decades ago. However, sometimes such
techniques are used to assist the
repurposing of a building or structure or
to ensure its continued life through a
change in environmental conditions.
Four key techniques feature again-andagain in our project portfolio – fiber
reinforced polymer (FRP) application,
bearing replacement, external posttensioning and Impressed Current Cathodic
Protection (ICCP). These are sometimes
used together and sometimes with other
specialist procedures, such as heavy lifting.
1
TECHNOLOGY
3
4
2
Bearing replacement
Typically, bearings are found in bridges
and form a cushion between the bridge
piers and the bridge deck. Replacing bridge
Fiber reinforced polymer
bearings, when they have reached the end
FRP has the advantage of being lightweight,
of their design life, requires the development
yet strong. Additional shear capacity,
of precise procedures and the application
flexural strength and ductility can be applied
of heavy lifting techniques – jacking – to
to beams, columns, slabs and walls by the
raise the bridge deck to allow removal and
application of fiber reinforced polymer
insertion of bearings.
materials – with minimal disturbance to
The type of challenges met and
occupancy and rentable asset space.
professionally executed by BBR Network
It is applied as a ‘wrap’ or in strips to
Members is well demonstrated by a project
strengthen weak or damaged concrete.
carried out on the Morshead Overpass in
Following the New Zealand earthquakes in
Melbourne, Australia. Here, there were two
2011, many concrete columns at The Palms
types of bearing – elastomeric and
Shopping Center in Christchurch needed
mechanical – and replacement procedures
repair. The local BBR Network Member,
for each type of bearing were specifically
BBR Contech, carried out repairs to the
designed. Working space limitations and
column extremities, including forming and
further structural issues led to the creation
pouring with fine aggregate concrete and
of prefabricated steel angle brackets to
structural mortar before confining the
support the jacks for replacement of the
columns with carbon fiber wrap.
elastomeric bearings. The replacement
In another project, this time executed by
method for the mechanical bearings was
BBR Polska, FRP strips were applied for
much simpler in terms of jacking, as there
strengthening to the underside of floor
was enough space on the crosshead to seat
slabs in an office building in Warsaw.
the jack behind the existing bearing. ➤
TECHNOLOGY
External PT strengthening
Also in Poland, girders supporting the
The use of externally placed post-tensioning
concrete slab of a staff car park in Siedlce
tendons to increase load carrying capacity
were discovered to be deflecting. BBR
is a well-established practice. In principle,
Polska was contracted to come up with
induced tensile stresses in concrete due to
a strengthening solution and to deliver,
additional loading can be negated by
install, stress and grout the tendons.
applying compressive stresses induced by
Stressing force was calculated for each
post-tensioning. The technique is used
girder individually and then four strand
mainly in bridges, where additional load
BBR VT CONA CME external tendons
carrying capacity is often required.
were installed under each steel girder.
For example, BBR VT CONA CMB external
band tendons were applied to three large
bridges on Germany’s A45 federal
5
motorway by BBR Network Member KBVT.
The bridges were built in the 1960s and 70s
and damage made the repairs a matter of
urgency. These emergency repairs have
ensured the continued service of the bridges
for a further ten years – by which time they
will have been replaced by new ones.
External post-tensioning can be applied to
buildings to increase structural strength.
“External tendons strengthen and increase
the load capacity of a structure and their
effect comes into play immediately after
they are stressed,” says Bartosz Lukijaniuk
of BBR Polska, “hence the technology often
being called ‘active’ strengthening.”
He and his team designed and installed the
external post-tensioning system for the
strengthening of three leaking concrete
tanks at Warsaw’s ‘South’ sewage plant.
The BBR VT CONA CME external system
was used, anchored in steel blocks fixed
to the corners of the tanks.
6
7
TECHNOLOGY
“External tendons
strengthen and increase
the load capacity of a
structure and their
effect comes into play
immediately after
they are stressed,”
8
Impressed Current Cathodic Protection
control corrosion on a section of the
Impressed Current Cathodic Protection
Central Expressway under the Singapore
(ICCP) systems are installed to inhibit the
River. There had been significant problems
corrosion of steel reinforcing bars in
with water seepage and chunks of concrete
concrete structures – particularly if the
had fallen from the tunnel ceiling. Early
latter are in aggressive marine
data collected has indicated that the system
environments. The systems operate by
will offer considerable savings in long-term
passing a low voltage current through
repair costs.
strategically placed anodes inserted into
The expertise of the BBR Network in the
the concrete which forces the reinforcing
area of maintenance, repair and retrofit or
steel into a cathodic state and protects it
renovation is founded on a long experience
from corrosion. The ICCP control system
and understanding of structures, as well
monitors and records performance.
as the professional, effective and safe
An ICCP system was installed by BBR
application of the latest technologies.
Contech on the Kaikorai estuary bridge in
As building and asset owners and
Dunedin, New Zealand. The system can be
managers seek to manage their risks –
monitored and adjusted as necessary. Strict
whether they are building new structures
operational specifications were applied
or repairing, protecting or strengthening
during the repair and installation work to
existing ones – the BBR Network is ready
protect the estuary’s wetlands ecosystem.
with robust, well thought-out solutions to
Meanwhile, in Singapore, BBR Construction
help them ensure structural resilience for
Systems installed an ICCP system to
the long term. ●
1 The roof structure of the Olivia Sports Hall,
Gdansk – consisting of ten 80m long 3D
steel trusses – was strengthened externally
with 18 BBR VT CONA CME tendons by
BBR Polska.
2 At The Palms Shopping Center, Christchurch,
New Zealand, many concrete columns
were repaired by BBR Contech using
fiber reinforced polymer wrap after the
2011 earthquakes.
3 The elastomeric and mechanical bearings on
Morshead Overpass, Melbourne, Australia
were replaced using innovative techniques
devised by local BBR Network Member,
Structural Systems.
4 Fiber reinforced polymer strips were applied
to the underside of floor slabs within the an
office building Warsaw by BBR Polska.
5 BBR VT CONA CMB external band tendons
were applied to strengthen three large
bridges on Germany’s A45 federal
motorway by BBR Network Member KB
Vorspann-Technik.
6 BBR Polska designed and installed the
external post-tensioning system – using the
BBR VT CONA CME external system – for
the strengthening of three leaking concrete
tanks at Warsaw’s ‘South’ sewage plant.
7 Deflecting girders supporting the concrete
slab of a staff car park in Siedlce were
strengthened by BBR Polska using four
strand BBR VT CONA CME external tendons
installed under each steel girder.
8 An ICCP system is monitored and adjusted by
BBR Contech on the Kaikorai estuary bridge
installation in Dunedin, New Zealand.
THINKING ALOUD
Paul Wymer, Managing Director of BBR Contech, the New Zealand-based BBR Network Member
shares some thoughts about how to adapt successfully to changed circumstances
EMBRACING NEW
BEGINNINGS
Over the past few years in New Zealand, we’ve all had to act and adapt to
changed circumstances that were caused by factors outside of our control.
After the Canterbury earthquakes, we deployed our people – according to
their skills, experience and expertise – to help in the recovery. Life here will
never be quite the same again – the ‘old normal’ has gone forever and we
are working together to establish a ‘new normal’. In a sense, this is a new
beginning for us and it has made me think about the wider issue of the global
economy and how a similar approach may be needed.
After one of the longest and deepest
brutal facts about what may lay ahead
recessions in living memory, we must
and be prepared to change our habits.
acknowledge that the world economy is,
This takes courage and conviction in this
at best, volatile and uncertain – and that it
‘new normal’ environment where the
may never return to what we previously
outcomes can be uncertain.
considered to be ‘normal’. Yet, as we look
We need to listen carefully to new people
around us, there are indeed businesses
and new ways of doing things – and then
which are prospering – even new businesses
apply all of our experience and wisdom to
starting – despite the vagaries of the
discovering how we can integrate these
economic climate. This is happening
insights to move forward successfully.
because we’re creating a new order of things
If we suppress these new ideas, we risk
– realigning ourselves and our aspirations to
standing still – and even worse, we will fail
compete in this challenging environment.
to encourage and exploit the maximum
We have begun a new phase in our journey.
from our new emerging talent.
It is one that must bring new people
The 2012 New Zealander of the Year,
together, foster different ways of thinking
Sir Ray Avery said “Live like you are going
and introduce new technologies into the
to die tomorrow and learn like you are
market to enable us to contend with our new
going to live forever.” We can gain some
circumstances. While our market strategies
inspiration from this as we diligently
might need a little polishing, the core values
pursue new ideas – not always without risk
which underpin everything we do must
– and at the same time nurture a strong
remain the same – dedication and
learning culture. These things certainly
commitment to innovation, collaboration,
help to expand our horizons, reset our
quality and service excellence.
personal navigation devices along the way
As we navigate down this new path, we
and make us ready and able to embrace
must all expand our thinking, face some
new beginnings. ●
BBR DIRECTORY
HEADQUARTERS
Bahnstrasse 23
8603 Schwerzenbach-Zurich
Switzerland
Tel +41 44 806 80 60
Fax +41 44 806 80 50
www.bbrnetwork.com
info@bbrnetwork.com
EUROPE
AUSTRIA
KB Vorspann-Technik GmbH
Schillerstrasse 25
5020 Salzburg
Tel +43 662 456516
Fax +43 662 456516-11
www.kb-vt.com
office@kb-vt.com
BELGIUM
see Netherlands
BOSNIA & HERZEGOVINA
see Croatia
BULGARIA
see Spain
CROATIA
BBR Adria d.o.o.
Kalinovica 3, 10000 Zagreb
Tel +385 1 3839 220
Fax +385 1 3839 243
www.bbr-adria.com
bbr-adria@bbr-adria.com
DENMARK
see Norway
ESTONIA
see Austria
FINLAND
see Norway
FRANCE
ETIC S.A.S.
3 rue de Marly
78 000 Versailles
Tel +33 1 39 50 11 20
Fax +33 1 39 50 11 03
www.etic-sas.fr
contact@etic-sas.fr
GERMANY
KB Vorspann-Technik GmbH
Furstenrieder Strasse 275
81377 Munchen
Tel +49 89 72 44 969-0
Fax +49 89 72 44 969-12
www.kb-vt.com
office@kb-vt.com
LATVIA
see Austria
RUSSIA
see Germany
LITHUANIA
see Austria
SERBIA
see Croatia
MONTENEGRO
see Croatia
SLOVENIA
see Croatia
NETHERLANDS
Spanstaal – Ballast Nedam Infra
Specialiteiten B.V.
Nijverheidstraat 12, 4143 HM Leerdam
Post Address: PO Box 236, 4140 AE Leerdam
Tel +31 345 63 92 00
Fax +31 345 61 91 07
www.spanstaal.nl
info@spanstaal.nl
SPAIN
BBR Pretensados y Técnicas Especiales, S.L.
Antigua Carretera N-III, Km. 31, 150
28500 Arganda del Rey, Madrid
Tel +34 91 876 09 00
Fax +34 91 876 09 01
www.bbrpte.com
bbrpte@bbrpte.com
NORWAY
KB Spennteknikk AS
Siva Industrial Estate, N. Strandsveg 19-21
Postboks 1213, 2206 Kongsvinger
Tel +47 62 81 00 30
Fax +47 62 81 00 55
www.spennteknikk.no
spennteknikk@spennteknikk.no
POLAND
BBR Polska Sp. z o.o. (Head Office)
ul. Annopol 14, 03-236 Warszawa
Tel +48 22 811 50 53
Fax +48 22 676 92 31
www.bbr.pl
bbrpolska@bbr.pl
BBR Polska Sp. z o.o.
ul. Tarnogorska 214a, 44-105 Gliwice
Tel +48 32 331 47 98
Fax +48 32 330 24 11
www.bbr.pl
bbrpolska.gliwice@bbr.pl
IRELAND
see United Kingdom
PORTUGAL
see Spain
KOSOVO
see Croatia
ROMANIA
see Spain
SWEDEN
Spännteknik AB
Sjöängsvägen 7,
192 72 Sollentuna
Tel +46 8 510 678 10
Fax +46 8 510 678 19
www.spannteknik.se
info@spannteknik.se
SWITZERLAND
Stahlton AG
Hauptstrasse 131
5070 Frick
Tel +41 44 938 99 00
Fax +41 44 422 11 16
www.stahlton.ch
info@stahlton.ch
UKRAINE
see Poland
UNITED KINGDOM
Structural Systems (UK) Ltd
12 Collett Way
Great Western Industrial Estate
Southall, Middlesex, UB2 4SE
Tel +44 20 8843 6500
Fax +44 20 8843 6509
www.structuralsystemsuk.com
info@structuralsystemsuk.com
BBR DIRECTORY
AFRICA
SOUTH AFRICA
Structural Systems (Africa)
Group Five House
9 Country Estate Drive
Waterfall Business Estate
Jukskei View
Johannesburg 2090
Tel +27 10 060 1555
Fax +27 86 616 7482
www.structuralsystemsafrica.com
info@sslafrica.com
MIDDLE EAST
BAHRAIN
see United Arab Emirates
SYRIA
see Jordan
JORDAN
Marwan Alkurdi & Partners Co. Ltd
PO Box 506, Amman 11821
Tel +962 6 581 9489
Fax +962 6 581 9488
www.mkurdi.com
ali@mkurdi.com
UNITED ARAB EMIRATES
NASA Structural Systems LLC
(Head Office)
Office M 03, Bu Shaqar Building
Garhoud
PO Box 28987
Dubai
Tel +971 4 2522 501
Fax +971 4 2522 502
www.bbrstructuralsystems.com
bbr@bbrstructuralsystems.com
KUWAIT
see Jordan
OMAN
Structural Systems Limited (Oman Branch)
Office A-11, Al Souroh Building
Al Ghala Industrial
PO Box 1946, PC-130
Muscat, Sultanate of Oman
Tel +968 2459 5279
Fax +968 2459 5252
QATAR
see United Arab Emirates
AMERICAS
EASTERN CANADA
Canadian bbr Inc.
3450 Midland Ave.
Scarborough
Ontario M1V 4V4
Tel +1 416 291 1618
Fax +1 416 291 9960
mducommun@bbrcanada.com
KINGDOM OF SAUDI ARABIA
Huta-Hegerfeld Saudia Ltd
BBR Prestressing Division
Prince Sultan St. Lotus Building
PO Box 1830, Jeddah 21441
Tel +966 12 662 3205
Fax +966 12 683 1838
www.hutahegerfeld.com.sa
bbr@huta.com.sa
Structural Systems Middle East LLC
Office 38, Sheikh Abdullah Bin Zayed Al Nahyan
Industrial Area
Musaffah-2
P O Box 126740
Abu Dhabi
Tel +971 2 5554 347
Fax +971 2 5554 348
Emirates & Australia Const.
Systems LLC
Office 112
Hatem Kamal Farah Building
Beirut Street
PO Box 62174
Sharjah
Tel +971 6 5437 490
Fax +971 6 5437 491
BBR DIRECTORY
ASIA PACIFIC
MALAYSIA
BBR Construction Systems (M) Sdn Bhd
No. 17, Jalan PJS 11/2
Bandar Sunway
46150 Subang Jaya
Selangor Darul Ehsan
Tel +60 3 5636 3270
Fax +60 3 5636 3285
www.bbr.com.my
enquiry@bbr.com.my
PHILIPPINES
BBR Philippines Corporation
Suite 502, 7 East Capitol Building
No.7 East Capitol Drive
Barangay Kapitolyo
Pasig City, Metro Manila 1603
Tel +632 638 7261
Fax +632 638 7260
jcf.admin@bbr.com.ph
SINGAPORE
BBR Construction Systems Pte Ltd
BBR Building
50 Changi South Street I
Singapore 486126
Republic of Singapore
Tel +65 6546 2280
Fax +65 6546 2268
www.bbr.com.sg
enquiry@bbr.com.sg
THAILAND
see Singapore
VIETNAM
see Singapore
AUSTRALIA
Structural Systems (Northern) Pty Ltd
20 Hilly Street, Mortlake
New South Wales 2137
Tel +61 2 8767 6200
Fax +61 2 8767 6299
www.structuralsystems.com.au
info@nsw.structural.com.au
Structural Systems (Northern) Pty Ltd
Unit 1/12 Commerce Circuit
Yatala, Queensland 4207
Tel +61 7 3442 3500
Fax +61 7 3442 3555
info@qld.structural.com.au
Structural Systems (Southern) Pty Ltd
PO Box 1303
112 Munro Street, South Melbourne
Victoria 3205
Tel +61 3 9296 8100
Fax +61 3 9646 7133
info@structural.com.au
Structural Systems (Southern) Pty Ltd
39 Howards Road
Beverley SA 5009
Tel +61 8 8268 0400
Fax +61 8 8268 0401
info@structural.com.au
Structural Systems (Western) Pty Ltd
3 Craig St, Burswood
Western Australia 6100
Tel +61 8 9267 5400
Fax +61 8 9267 5499
info@wa.structural.com.au
FIJI
see New Zealand
NEW ZEALAND
BBR Contech
6 Neil Park Drive, East Tamaki
PO Box 51-391
Pakuranga, Auckland 2140
Tel +64 9 274 9259
Fax +64 9 274 5258
www.contech.co.nz
akl@contech.co.nz
BBR Contech
38 Waione Street, Petone
PO Box 30-854
Lower Hutt, Wellington 5040
Tel +64 4 569 1167
Fax +64 4 569 4269
www.contech.co.nz
wgn@contech.co.nz
BBR Contech
7A Birmingham Drive, Middleton
PO Box 8939
Riccarton, Christchurch 8440
Tel +64 3 339 0426
Fax +64 3 339 0526
www.contech.co.nz
chc@contech.co.nz
Additional BBR technology licenses have been granted in Europe, Asia Pacific and Americas – for more information, please contact the BBR Headquarters.
CONNÆCT
The magazine of the Global BBR Network of Experts
2013

Connaect 2014

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